Systems and methods for 3D printing with multiple exchangeable printheads

ABSTRACT

A modular 3D printer system can include a base subsystem and multiple exchangeable components. The base subsystem can have a 3D motion module, a printhead module and a platform module. The multiple exchangeable components can include printheads having different configurations and functionalities, which can be exchangeably installed in the printhead module. The multiple exchangeable components can include platform supports having different configurations and functionalities, which can be exchangeably installed in the platform module.

The present application is a continuation of application Ser. No.15/810,014, filed on Nov. 11, 2017, entitled “Systems and methods for 3Dprinting with multiple exchangeable printheads” (HYREL001A), which is acontinuation-in-part of application Ser. No. 14/578,309, filed on Dec.19, 2014, entitled “Systems and methods for 3D printing with multipleexchangeable printheads” (HYREL001), which claims priority from U.S.Provisional Patent Application Ser. No. 61/929,114, filed on Jan. 19,2014 entitled “3D printer systems and methods” (HYREL001-PRO), U.S.Provisional Patent Application Ser. No. 61/918,650, filed on Dec. 19,2013, entitled “3D printer systems and methods” (HYREL002-PRO), U.S.Provisional Patent Application Ser. No. 61/929,136, filed on Jan. 20,2014, entitled “3D printer systems and methods” (HYREL003-PRO) and U.S.Provisional Patent Application Ser. No. 61/972,613, filed on Mar. 31,2014, entitled “3D printer systems and methods” (HYREL004-PRO), all ofwhich are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

3D printers can be used to build solid objects by printing layers bylayers of building materials. The building materials can be in liquid orsemi liquid form at the 3D printhead, for example, a solid material canbe heated and then extruded from a 3D printer nozzle. The layers ofbuilding materials can be solidified on a substrate.

3D printer systems can use a fused filament fabrication (FFF) process(sometimes called fused deposition modeling (FDM) process) in which afilament is moved, e.g., by a filament moving mechanism, toward a heatedzone. The filament can be melted, and extruded on a platform to form a3D object. The melted filament can adhere to the walls of the heatedprinthead, resulting in deformed printed lines.

It would therefore be advantageous to have advanced 3D printing systemsand methods that have improved printing mechanisms.

SUMMARY OF THE EMBODIMENTS

In some embodiments, the present invention discloses a modular system,including a base subsystem and multiple exchangeable components. Themodular system can be a 3D printer system, having a base subsystemincluding a 3D (with 3 or more degrees of freedom) motion module, aprinthead module and a platform module. The multiple exchangeablecomponents can include printheads having different configurations andfunctionalities, which can be exchangeably installed in the printheadmodule. The multiple exchangeable components can include platformsupports having different configurations and functionalities, which canbe exchangeably installed in the platform module.

The printhead configurations and functionalities can include printheadshaving nozzles extruding materials with different cross sections,printheads having fan blowing to the extruded materials, printheadshaving tilted nozzles, printheads having in-situ or ex-situ debriscleaning mechanisms, printheads having agitation mechanisms, printheadshaving pre-heating mechanisms, printheads having radiation curingmechanisms, printheads having multiple filaments, printheads havingmechanisms to extrude paste-like or liquid-like materials, printheadshaving mechanisms for writing, and printheads having mechanisms forcutting and milling.

The platform support configurations and functionalities can includehorizontal platform supports, vertical platform supports, platformshaving vertical and horizontal supports, platforms with watermarks, andclamp platforms.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B illustrate 3D printer systems according to some embodiments.

FIGS. 2A-2C illustrate schematics of printer systems according to someembodiments.

FIGS. 3A-3B illustrate a communication system for 3D printer systemsaccording to some embodiments.

FIGS. 4A-4D illustrate a communication system for 4D printer systemsaccording to some embodiments.

FIGS. 5A-5D illustrate alignment configurations for printheads accordingto some embodiments.

FIGS. 6A-6B illustrate methods to operate a modular printing systemaccording to some embodiments.

FIGS. 7A-7D illustrate printhead configurations according to someembodiments.

FIGS. 8A-8D illustrate printhead configurations according to someembodiments.

FIGS. 9A-9C illustrate printhead configurations according to someembodiments.

FIGS. 10A-10D illustrate printhead configurations according to someembodiments.

FIGS. 11A-11D illustrate platform configurations in a modular systemaccording to some embodiments.

FIGS. 12A-12B illustrate printheads having different nozzle patternsaccording to some embodiments.

FIG. 13 illustrates 3D printer systems and printheads according to someembodiments.

FIGS. 14A-14F show different print head nozzles.

FIGS. 15A-15D illustrate a schematic mechanism for forming overhangfeatures without support structures according to some embodiments.

FIGS. 16A-16C illustrate overhang features for a tilted nozzle accordingto some embodiments

FIGS. 17A-17B illustrate a printing process of a horizontal overhangaccording to some embodiments.

FIGS. 18A-18B illustrate rotatable nozzles according to someembodiments.

FIGS. 19A-19B illustrate rotatable nozzles according to someembodiments.

FIGS. 20A-20B illustrate printheads having remote heaters for the nozzleaccording to some embodiments.

FIGS. 21A-21B illustrate flow charts for operating print heads having atilted nozzle according to some embodiments.

FIGS. 22A-22B illustrate flow charts for operating print heads having atilted nozzle according to some embodiments.

FIG. 23 illustrates a 3D printer system having a tilted nozzle and acooling mechanism.

FIGS. 24A-24C illustrate flow charts for printheads having a coolingmechanism according to some embodiments.

FIGS. 25A-25B illustrate printheads having a cleaning mechanismaccording to some embodiments.

FIGS. 26A-26C illustrate integrated printheads having cleaningmechanisms according to some embodiments.

FIGS. 27A-27B illustrate printheads having exposure sections accordingto some embodiments.

FIGS. 28A-28B illustrate a cleaning operation according to someembodiments.

FIGS. 29A-29B illustrate flow charts for printer systems having anintegrated cleaning system according to some embodiments.

FIGS. 30A-30B illustrate flow charts for operating printer systemshaving an integrated cleaning mechanism according to some embodiments.

FIGS. 31A-31B illustrate flow charts for operating printer systemshaving an integrated cleaning mechanism according to some embodiments.

FIGS. 32A-32F illustrate various configurations of printhead assembliesaccording to some embodiments.

FIGS. 33A-33B illustrate flow charts for forming a 3D printhead assemblyaccording to some embodiments.

FIGS. 34A-34B illustrate flow charts for operating 3D printer assembliesaccording to some embodiments.

FIGS. 35A-35D illustrate different radiation sources according to someembodiments.

FIGS. 36A-36B illustrate different radiation sources according to someembodiments.

FIGS. 37A-37B illustrate a printing process of printhead having aradiation source according to some embodiments.

FIGS. 38A-38C illustrate flow charts for forming print heads having aradiation source according to some embodiments.

FIGS. 39A-39B illustrate flow charts for forming print heads having aradiation source according to some embodiments.

FIGS. 40A-40C illustrate flow charts for operating print heads having aradiation source according to some embodiments.

FIGS. 41A-41B illustrate flow charts for operating print heads having aradiation source according to some embodiments.

FIGS. 42A-42D illustrate different printheads according to someembodiments.

FIGS. 43A-43B illustrate a printhead having multiple inputs and onemixed output according to some embodiments.

FIGS. 44A-44C illustrate a printhead having a spinning mixer accordingto some embodiments.

FIGS. 45A-45B illustrate flow charts for printer systems having arotatable mixer according to some embodiments.

FIGS. 46A-46C illustrate a printhead having a spinning mixer accordingto some embodiments.

FIGS. 47A-47B illustrate flow charts for printer systems having arotatable mixer according to some embodiments.

FIGS. 48A-48C illustrate different print heads according to someembodiments.

FIG. 49 illustrates a peristaltic print head according to someembodiments.

FIG. 50 illustrates a printing system using a peristaltic pump accordingto some embodiments.

FIGS. 51A-51B illustrate flow charts for printing liquid materialsaccording to some embodiments.

FIGS. 52A-52C illustrate a printing system according to someembodiments.

FIG. 53 illustrates a 3D printing system according to some embodiments.

FIG. 54 illustrates a flow chart for 3D printing according to someembodiments.

FIGS. 55A-55C illustrate 3D printer systems according to someembodiments.

FIGS. 56A-56B illustrate patterning processes on printed objectsaccording to some embodiments.

FIGS. 57A-57D illustrate patterned platforms according to someembodiments.

FIGS. 58A-58E illustrate a process of forming a recess pattern on alayer on a platform according to some embodiments.

FIGS. 59A-59B illustrate top surfaces of patterned platforms accordingto some embodiments.

FIGS. 60A-60C illustrate flow charts for 3D printer systems havingpatterned platforms according to some embodiments.

FIGS. 61A-61B illustrate a printing process for a printer having atemperature controlled platform according to some embodiments.

FIGS. 62A-62B illustrate flow charts for printer systems having aPeltier device platform according to some embodiments.

DETAILED DESCRIPTION OF THE EMBODIMENTS

In some embodiments, the present invention discloses systems and methodsfor 3D printing, using multiple exchangeable printheads. In general, thenumber of desired printheads can exceed the capacity of a 3D printer,thus exchangeable printheads can accommodate the needs of 3D printingrequirements without significantly affect the complexity and cost of 3Dprinter systems. For example, a typical 3D printer can have a limitednumber of printheads, such as 1-4 printheads. The number of desiredprintheads can easily be greater than 4, for example, multipleprintheads can be required to handle different filament colors,different nozzle sizes, different types of printheads such as filamentprintheads, paste printheads, liquid printheads, and differentprintheads with different specifications.

In some embodiments, the present invention discloses systems and methodsto accommodate the diversity requirements of having multiple printheadswith exchangeable printheads. Recognizing that different printheads canbe required for different jobs, a 3D printer with exchangeableprintheads can be used in which the desired printheads for theparticular job can be selected and installed before printing theworkpiece.

In some embodiments, the present invention discloses a base systemhaving a printhead module. The printhead module can have one or moreinstalled printheads. The printhead module can be configured to acceptone or more printheads, e.g., the printhead module can have mechanicalinterfaces for mechanically mating with printheads, and have electricalinterfaces for electrically connected to the printheads. Mechanicaland/or electrical coupling can be used, for example, to align and toconfigure the newly installed printhead to form a complete system, e.g.,a 3D printer with desired printheads for the jobs.

In some embodiments, the present invention discloses printheads havingmechanical and electrical interfaces for coupling with a printheadmodule of a base system. The printheads can have a mechanical systemcoupled to the mechanical interface for processing a workpiece, such asprinting the workpiece. For example, the printheads can include a motorand a hotend for extruding plastic from a plastic filament. Theprintheads can have an electrical system coupled to the electricalinterface for controlling the printheads, such as operating or notoperating the mechanical portion of the printheads. For example, theelectrical system can instruct the printheads to print on a platform, orto instruct the printheads to move without printing.

There can be different printheads for different job requirements. Forexample, printheads to accommodate filament printing such as fusedfilament fabrication printheads, printheads to accommodate pasteprinting such as plunger style printheads, printheads to accommodateliquid printing such as printheads with peristaltic pumps, printheadswith different color printing materials, printheads with differentnozzle openings for printing different sizes of material, and printheadswith special requirements for special materials such as printheads withUV cured radiation for cross linking polymer materials.

Additive manufacturing processes generally fabricate 3D objects bydepositing layers by layers in patterns corresponding to the shape ofthe objects. At each layer, a print head can deposit building materialsat locations corresponded to the pattern of the object for that layer.

3D printing processes can include inkjet printing, stereolithography andfused filament fabrication. In inkjet printing processes, liquidmaterial are released from an inkjet print head, and solidified on thesubstrate surface, e.g., on the model being formed. In stereolithographyprocesses, a UV light can crosslink layers of photopolymer. In fusedfilament fabrication processes, a continuous filament of thermoplasticcan be softened or melted and then re-solidified on a previouslydeposited layer. Alternatively, paste-like materials can be used forprinting, for example, through a pressure extrusion device such as apiton/cylinder.

Various polymers are used, including acrylonitrile butadiene styrene(ABS), polycarbonate (PC), polylactic acid (PLA), high densitypolyethylene (HDPE), PC/ABS, and polyphenylsulfone (PPSU). Othermaterials can be used, such as clay or ceramic materials.

FIGS. 1A-1B illustrate 3D printer systems according to some embodiments.FIG. 1A shows a mechanical schematic and FIG. 1B shows an electricalschematic of a 3D printer system. The 3D printer system can include aprinthead module 110 for printing an object 150 on a platform module130. The printhead module 110 can include a delivery module 117, whichis configured to deliver printing materials to a print head 111. Theprint head 111 can be heated by a heater 116, for example, to atemperature that can soften or melt the printing materials. The deliverymodule can push the melted printing materials through the print head111, so that the printing materials can be deposited on the platform 131of the platform module 130 to form a printed object 150. The printheadmodule 110 can accommodate multiple printheads, e.g., one or moreprintheads 112 in addition to printhead 111.

The printhead module 110 can include other components, such as a thermalisolation element, disposed between the heated print head 115 and thedelivery module 117, for example, to prevent heating the suppliedprinting materials in the delivery module 117. The platform module 130can include other components, such as a heater 132, which can heat theplatform surface.

The 3D printer system can include a motion module 120, which can beconfigured to provide motions of the printhead module 110 relative tothe platform module 130, in 3D motions, such as x, y, and z directionsin linear 3D printer systems, or 3 z directions in delta 3D printersystems. For example, the printhead can move in a horizontal direction,such as x. The platform can move in a horizontal direction such as y,together with a vertical direction such as z. Other movementconfigurations can be used to provide complete 3D movements of theprinthead relative to the platform.

The 3D printer system can include a controller module 140, for example,a computer or a microcontroller for controlling the printhead module,the motion module, and the platform module.

In some embodiments, the present invention discloses a 3D printer systemwith exchangeable components. The modules of the 3D printer system,e.g., the printhead module and the platform module can have interfacesfor exchanging components. For example, different printheads can becoupled to the printhead module, e.g., existing printheads can beremoved from the printhead module, and new printheads can be installedto the printhead module. Different workpiece supports can be coupled tothe platform module, e.g., the workpiece support can be exchanged toaccommodate different workpieces.

A printhead can be configured for extruding from a filament material. Afilament, such as a thermoplastic filament, can be provided to adelivery module. The delivery module can include a mechanism to regulatethe flow of filament material. For example, a worm-drive or rotatinggears can be used to push the filament into the printhead at acontrolled rate. The printhead can include a heater, which can heat thefilament material to a temperature that can melt or soften the filamentmaterial, for example, to a temperature higher than the glass transitiontemperature of the filament material. The printhead can be thermallyisolated from the delivery module, for example, by a low temperaturecoefficient material.

A printhead can be configured for extruding from a paste-like material.Paste-like material, such as plasticine or a ceramic paste, can beprovided to a delivery module. The delivery module can include amechanism to deliver the paste-like material, such as a piston/cylinderconfiguration. For example, a paste-like material can be disposed in acylinder, and can be pressed by a piston so that the paste-like materialcan be pushed into the printhead at a controlled rate.

A printhead can be configured for extruding from a liquid-like material.Liquid-like material, such as liquid polymer, can be provided to adelivery module. The delivery module can include a mechanism to deliverthe liquid-like material, such as a liquid pump configuration. Forexample, a liquid-like material can be disposed in a reservoir, and canbe pumped by a peristaltic pump so that the liquid-like material can bedelivered to a platform support at a controlled rate.

Other printheads can be used, such as a laser head for cuttingmaterials, a cutter head for removing materials from the workpiece, anda pen head for writing on the workpiece. The different printheads can bedescribed in greater details in subsequent sections.

The platform module can have exchangeable components. For example, aplatform module can include a horizontal flat platform, e.g., workpiecesupport, for supporting a workpiece. The flat platform can havedifferent watermark designs for imprinting on a bottom surface of theprinted workpiece. The platform module can include a vertical flatplatform with different watermark designs for imprinting on a sidesurface of the printed workpiece. The platform module can include aclamp mechanism for holding the workpiece. The different workpiecesupports can be described in greater details in subsequent sections.

In some embodiments, the present invention discloses 3D printer systems,and methods to build and operating the printer systems, that are modularand that can allow automatic configurations of components, such asdifferent printheads. The 3D printer systems can utilize multipleprintheads, each with different functionality and/or characteristic. Forexample, a printhead can be used for extruding filament materials.Another printhead can be used or extruding paste-like materials.Different printheads can be used for extruding materials havingdifferent colors. Printheads having different nozzle configurations,e.g., small nozzles, large nozzles, single nozzle, multiple nozzles,etc., can be used to optimize the printing process, such as fasterprinting throughput.

In some embodiments, the present invention discloses 3D printer systemshaving multiple printheads, with at least one printhead different fromat least another printhead. The different printheads can extend thefunctionality of the 3D printer, e.g., allowing the printer to printwith different printing characteristics provided by the differentprintheads.

In some embodiments, the printer systems can allow ease of exchange ofprintheads. For example, installed printheads can be removed from theprinter systems. New printheads can be installed to the printer systems.The printhead exchange can be performed manually by an operator withoutusing any tools, e.g., the exchange process can be performed by hand.Further, the printhead exchange can be performed without shutting downthe system, e.g., like in a repair or a replacement of a defectiveprinthead. The printhead exchange can be performed while the system isstill in operation, which can be defined in the present specification aspower is still on in the system, calibration and data of the system arenot lost, and other parts of the system do not need to be calibrated dueto the exchange.

The printer systems can automatically recognize the installed printheadsand the printer systems can be reconfigured accordingly to accommodateand use the printheads in the systems. The exchange of printheads can beperformed manually, e.g., by an operator, or automatically, e.g.,controlled by printing process software.

In some embodiments, a controller system can be provided to the printersystem to allow the reconfiguration of the configuration of the printersystem to recognize the removal or adding printheads when there arechanges in printhead configurations. For example, electrical connectionsto a printhead can be broken when the printhead is removed from theprinter system, resulting in the system controller recognizing that theprinthead is no longer available. Similarly, electrical connections to anew printhead can be established when the new printhead is installed inthe printer system, resulting in the system controller recognizing thatthe new printhead is becoming available. The electrical connections canbe performed by hardwires, e.g., manually connected by an operator wheninstalling a new printhead, or manually disconnected when removing anexisting printhead. The availability of a new printhead can also beidentified by the system controller through the setting of multiplesignals to control the new printhead, such as controlling a heater forheating the printhead, a motor for controlling the delivery of printingmaterials, a motor for cleaning debris from the printhead, and theidentification of the printhead.

In some embodiments, the printheads can be different from each other.For example, a printhead can have a printing characteristic differentfrom other printheads, e.g., having a unique characteristic related tothe printing process. The printing characteristics can include theprinting materials, e.g., the different materials that the printheadscan print. For example, a printhead can print a medium meltingtemperature polymer such as ABS, PLA, or nylon. A printhead can print ahigh melting temperature polymer such as PEEK. A printhead can print aroom temperature paste material like clay. A printhead can print a lowtemperature paste material like wax. A printhead can print a mixture oftwo or more materials like rubber or epoxy having 2 components.

The printing characteristics can include a maximum temperature of theprintheads, e.g., the highest temperature that the printhead canachieve. The temperature characteristic can be linked to the materialcharacteristics, such as low melting temperature materials can use a lowmaximum temperature printhead, and high melting temperature materialscan use a high maximum temperature printhead. For example, a printheadcan have a maximum temperature setting of room temperature, which can beused for printing room temperature materials such as clay. A printheadcan have a low temperature setting of less than 100 C, which can be usedfor printing low melting materials such as common wax or some biologymaterials. A printhead can have a medium temperature setting of between100 C and 300 C, which can be used for printing medium melting materialssuch as ABS, PLA, or nylon. A printhead can have a high temperaturesetting of between 300 C and 500 C, which can be used for printing highmelting materials such as PEEK.

The printing characteristics can include a configuration of theprintheads, e.g., the direction of the materials delivered to theplatform. For example, a printhead can have a nozzle straight down, forprinting a flat layer. A printhead can have the nozzle making an angledifferent from zero to the vertical line, for printing on anon-horizontal surface. Other configurations can be included, such as acooling fan for cooling the material already printed, an infrared lampfor heating the already printed material for keeping the printed objectat an elevated temperature, or a UV lamp for UV curing the printedmaterial.

The printing characteristics can include a method of delivering theprinting materials. For example, a printhead can include a motor forpushing a filament to a hot zone. A printhead can include apiston-syringe assembly for pushing a paste-like material. A printheadcan include liquid delivery system for delivering a liquid, e.g., aliquid material at room temperature and can turn into a solid whenreaching a cold platform, such as 3D printer using water for printingice sculpture. The liquid delivery system can include a liquid pump,such as a peristaltic pump, a gear pump, or a rotary pump.

Other printing characteristics can be included, such as an inkjetcharacteristic for an inkjet printhead, or a laser characteristic for alaser printhead.

In some embodiments, the present invention discloses a 3D printer systemwith multiple printheads. The printheads can be different from eachother, such as having a distinct characteristic. In some embodiments,the system may not be limited to a 3D printer system, but can includeother systems, such as hybrid systems that can print 3D objects, but canalso cut or engrave by a laser printhead, or can mark by a penprinthead. A 3D printer system can include a system that can perform 3Dprinting using a 3D printing printhead. But the 3D printer system is notlimited to only 3D printing. The 3D printer system can also be used forother processes, such as laser engrave or laser cutting or laser foldingusing a laser printhead, milling or drilling or lathing using a millprinthead, or writing using a pen printhead.

The printheads can be coupled to the 3D printer system through amechanical interface and optionally an electrical interface. Forexample, the 3D printer system can have one or more mechanicalinterfaces. Each mechanical interface can be configured to mate with amechanical interface on a printhead. Thus, by coupling the twointerfaces, a printhead can be mechanically installed to the 3D printersystem. Similarly, by decoupling the interfaces, the printhead can beremoved from the 3D printer system.

The mechanical interfaces can be configured for ease of installation,for example, by an operator without using any tool, or using only simpletools such as a screw driver or a wrench. The mechanical interfaces canbe removably coupled to each other. The mechanical interfaces can beconfigured so that the printheads can be installed or removed while thesystem is still in operation, e.g., without shutting down the system, orwithout recalibrating the system. For example, the system can stopprinting, and an operator can remove an installed printhead, and theninstall a new printhead. The system then can resume printing.

In some embodiments, the mechanical interfaces can be configured so thatthe printheads can be installed or removed automatically, e.g., by aprinthead exchange mechanism. The printhead exchange can be performed aspart of the operation of the system, e.g., the system can print with aninstalled printhead, stop the printing, exchange the printhead foranother printhead, and then resume printing. Thus the 3D printer canhave the printhead exchange while still in operation, meaning notshutting down or power down.

In some embodiments, the mechanical interfaces can include a magneticcoupling, using permanent magnets or electromagnets. The magneticcoupling can simplify the mechanical connection between the printheadand the 3D printer, such as providing self-alignment, e.g., when aprinthead is brought into a vicinity of the 3D printer, the printheadcan automatically couple to the correct location, through the magneticforce alignment.

In some embodiments, the installation of the printheads can include analignment mechanism. Since the printheads can be installed and removedand re-installed, the positions of the printheads cannot be determinedaccurately, due to the possible changes of the positions of theprintheads when the printheads are installed. Thus the alignmentmechanism can be used for determining the positions of the installedprintheads.

The alignment mechanism can include a mechanical alignment mechanism,which can be used to mechanically set the printheads to have apredetermined offset distance, for example, to a fixed location such asthe printhead module. For example, the mechanical alignment mechanismcan include a stop element, and the printhead can be pushed, by thealignment mechanism, so that the printhead contacts the stop element.That can ensure that the printhead is installed with a predeterminedoffset distance.

The 3D printer system can have one or more electrical interfaces. Eachelectrical interface can be configured to mate with an electricalinterface on a printhead. Thus, by coupling the two interfaces, aprinthead can be electrically installed to the 3D printer system.Similarly, by decoupling the interfaces, the printhead can beelectrically removed from the 3D printer system. The electricalinterfaces can be optional on the printheads, e.g., some printheads donot have electrical components, and thus the printheads may not haveelectrical interfaces.

The electrical interfaces can include mated connectors, e.g., a maleconnector can be on the 3D printer interface, and a corresponding femaleconnector can be on the printhead interface, or vice versa. To ease theconnection, the electrical interfaces can include only one matedconnector, e.g., one connector on the 3D printer and a mated connectoron the printheads.

The electrical interfaces can include wireless communication, e.g., atransmitter can be on the 3D printer interface, and a correspondingreceiver can be on the printhead interface, or vice versa. Usingwireless communication, the coupling of the electrical interfaces can bea non-contact coupling, and the non-contact coupling can be performed bysoftware, e.g., without operator intervention, or without operatoractually connecting the electrical interfaces.

The coupling and decoupling of the electrical interfaces can be similarto the coupling and decoupling of the mechanical interfaces. Forexample, the electrical interfaces can be coupled or decoupled by anoperator without using any tool. The electrical interfaces can beremovably coupled to each other. The electrical interfaces can beconfigured so that the printheads can be installed or removed while thesystem is still in operation, e.g., without shutting down the system, orwithout recalibrating the system. For example, the system can stopprinting, and an operator can remove an installed printhead, and theninstall a new printhead. The system then can resume printing.

In some embodiments, the electrical interfaces can be configured so thatthe printheads can be installed or removed automatically, e.g., by aprinthead exchange mechanism. The printhead exchange can be performed aspart of the operation of the system, e.g., the system can print with aninstalled printhead, stop the printing, exchange the printhead foranother printhead, and then resume printing. Thus the 3D printer canhave the printhead exchange while still in operation, meaning notshutting down or power down. The automatic printhead exchange can beeasily performed using wireless communication, e.g., the electricalinterfaces using wireless communication through a transmitter and areceiver.

In some embodiments, the electrical interfaces can be configured to behot-swappable, meaning coupling the electrical interfaces withoutstopping or shutting down the system. The printheads can be installedand removed from the 3D printer without interruption to the 3D printer.In a hot swappable connector, ground pins can be connected beforeconnecting sensitive circuitry, e.g., the hot swapping connector ensuresthat no sensitive circuitry is connected before there is a reliablesystem ground. The connector can have staggered pins to allow the groundpin to be connected before other pins. The other pins can be configuredso that the incoming device can be grounded first, followed by the datalines, and lastly by the power.

The hot swappable connector can include pre-charged pins that makecontact before the main power pins. The pre-charge pins can be protectedby a current limiter circuit that limits the inrush current to anacceptable value. The current limiter circuit can be a series resistor,a negative temperature coefficient (NTC) resistor, or othercurrent-limiter circuits. Soft-start circuit can also be used to providea ramp-up of the voltages to prevent excessive high contact current.

The alignment mechanism can include an electrical alignment mechanism(instead of a mechanical alignment mechanism), which can be used todetermine offset distance of the printheads, for example, to a fixedlocation such as the printhead module. For example, the electricalalignment mechanism can include a distance sensor, such as an ultrasonicsensor or a laser sensor, which can be used to determine the offsetdistance of the printheads to a fixed location. The offset distance thencan be communicated to the controller module, which can use the offsetdistance to know the precise location of the newly installed printheads.

In some embodiments, the mechanical interfaces and the electricalinterfaces can be integrated, meaning the coupling or decoupling of themechanical interfaces can automatically couple or decouple theelectrical interfaces. For example, the electrical interfaces caninclude a connector disposed at an end of a mechanical coupling. Thus byperforming the mechanical coupling, at the end of the mechanicalcoupling process, the electrical connector in the printhead can matewith the electrical connector of the 3D printer. Similarly, whenmechanically decouple the printhead, the electrical connector aredecoupled first, followed by the decoupling to the mechanical coupling.Thus at the end of the decoupling process, both electrical andmechanical couplings have been decoupled.

In some embodiments, one or more printheads can be installed in the 3dprinter system, for example, by coupling the mechanical and electricalinterfaces of the printheads with the 3D printer system. There can beone or more printheads available, e.g., not installed in the 3D printersystem. The available printheads can have a printing characteristicdifferent from the installed printheads, e.g., the 3D printer system canhave many printheads with different printing functions orcharacteristics, and the printheads that are needed for a current jobcan be installed in the 3D printer system to perform the job.

For a next job, the requirement can be changed, and thus an availableprinthead can be required. An installed printhead can be removed fromthe system, and the required available printhead can be installed, forexample, to the slot vacated by the removal of the removed printhead.

In some embodiments, the 3D printer system can include a platform modulethat is configured to support the workpiece, e.g., to support theprinted objects. The platform module can include a separate workpiecesupport, or the platform can be the workpiece support. The workpiecesupport can be removably coupled to the 3D printer system, for example,through mechanical interfaces and optionally electrical interfaces,similar to the concept of removably coupling of the printheads.

In some embodiments, the 3D printer system can include one or moreworkpiece supports. The workpiece supports can be different from eachother, e.g., having a distinct characteristic related to a printingprocess. For example, a workpiece support can include a horizontal flatsurface for printing an object on the horizontal surface. A workpiecesupport can include a vertical flat surface for printing an object onthe vertical surface. A workpiece support can include a flat surfaceforming an angle with the horizontal or vertical surface for printing anobject at an angle. A workpiece support can include a curved surface,such as a cylindrical or a spherical surface. A workpiece support caninclude a stationary flat or curved surface or a rotating flat or curvedsurface. A workpiece support can include a plain flat or curved surface,or a decorating plain flat or curved surface, e.g., a surface with awatermark that can imprint on the object to be printed on the decoratingsurface. A workpiece support can include a heater or a cooler surface,e.g., a room temperature surface, a hot surface, or a cold surface.

The workpiece supports can include mechanical interfaces, for example,to secure the workpiece supports to the 3D printer system. The platformor the 3D printer system can have a mechanical interface and theworkpiece supports can have a mating mechanical interface. Themechanical interfaces can include an alignment mechanism, to determinethe position and orientation of the installed workpiece support.

The workpiece supports can include electrical interfaces, for example,to provide power or signal to the workpiece supports. Some workpiecesupports can be purely mechanical, such as a horizontal flat workpiecesupport, or a cylindrical surface workpiece support, or a workpiecesupport having watermark. Some workpiece supports can require powerand/or signal, such as a heated or cooled workpiece supports, or arotating workpiece support. The platform or the 3D printer system canhave an electrical interface and the workpiece supports can have amating mechanical interface, if required. Thus, some workpiece supportsdo not have the electrical interface, and do not need to electricallyconnect to the 3D printer system. Some workpiece supports can require anelectrical interface, which can be coupled to the mated electricalinterface in the 3D printer system.

In some embodiments, the 3D printer system can include a motion module.The motion module can be configured to move the printhead modulerelative to the platform module, for example, in 3 dimensions, such asx, y, z, or r, theta, z, or delta style.

In some embodiments, the 3D printer system can include a controllermodule. The controller module can be configured to accept the installedprintheads by recognizing the printing characteristics of theprintheads. The controller module can have the characteristic profilesof the printheads, e.g., different profiles containing the printingcharacteristics of the different printheads. For example, the controllercan include the characteristic profiles. Alternatively, when a printheadis installed, the controller can communicate with the installedprinthead to obtain the characteristic profile of the installedprinthead. The controller can obtain the printing characteristics of theprinthead and then formulate the profile. Thus the characteristicprofiles of different printheads can contain the differences in theprinting characteristics of the printheads.

In some embodiments, when an installed printhead is removed, thecontroller can recognize that the printhead is removed, for example,through the electrical interfaces. Thus any attempt to operate theprinthead will result in a notification saying that the printhead is notavailable.

When a new printhead is installed, the controller can use thecharacteristic profile of the new printhead as the operating limits forsetting conditions for running the new printhead. The characteristicprofile can be obtained from a storage, e.g., the controller alreadycontains many different characteristic profiles for differentprintheads. The characteristic profile can be obtained by the controllerreading from the newly installed printhead, such as reading the wholeprofile, or reading the characteristics for building the profile. Thecontroller thus can be configured to accept the newly installedprinthead for operation.

In some embodiments, the present invention discloses 3D printer systemsconfigured to accept any of multiple printheads, with at least oneprinthead different from at least another printhead. A controller can beconfigured to accept the different printheads, either by storing thecharacteristic profiles of the printheads, or by having capability toread the profile or the characteristics of the printheads when theprintheads are installed in the system.

In some embodiments, the present invention discloses 3D printer systemshaving a controller configured to accept the different printheadsthrough a CAN bus. The CAN bus can allow an automatic configuration ofthe printheads with minimum number of connections, e.g., the controllercan be a CAN bus node, communicating with the installed printhead, whichis another CAN bus node.

FIGS. 2A-2C illustrate schematics of printer systems according to someembodiments. In FIG. 2A, a printer system 200 can include a platform230, for example, to move in xy directions. The printer system 200 caninclude a vertical movement module 220 to move the platform in a zdirection. The printer system 200 can include a printhead module 215,which can be configured to support multiple printheads 210, 211, and212. The above description xyz movements are illustrative, and otherconfigurations can be used, such as a platform 230 having an x movement,and the printhead module 215 having a y movement.

The printhead module 215 can accommodate one or more printheads 210 and211. In addition, new printheads 212 can be installed to the printheadmodule 215, and installed printhead 210 or 211 can be removed from theprinthead module 215.

The printer system can include a controller 240 for controlling themotors, e.g., motors to control the x, y, z movements, and other motionsand sensing assemblies. The printhead 210 and 211 each can have acontroller 250 for controlling the peripherals of the printhead, such asdelivery motor, cleaning fan, heater, etc. Mechanical coupling 261/271can be included for coupling the printheads to the printhead module. Asshown, the mechanical coupling can include mating shapes between theprintheads and the printhead module. For example, the printheads caninclude a taper shape 261, which can be mated to the taper opening 271in the printhead module. Electrical coupling 260/270 can be included forcommunication between the printer controller 250 and the printheadcontroller 240. For example, the printheads can include electricalcoupling 260, which can be electrically mated, e.g., connected, with theelectrical coupling 270 in the printhead module. Thus the printer systemcan communicate and recognize the installed printheads, e.g., throughthe electrical connection 260/270. As shown, the printheads can bemanually exchanged, e.g., an operator can remove and install a printheadin a printer system. Further, the mechanical and electrical couplings,which can be called mechanical and electrical interfaces between theprintheads and the printhead module, can be integrated. For example, theelectrical coupling 260/270 can be configured so that when theprintheads is mechanical coupled with the printhead module, through thecoupling 161/271, the electrical couplings 260/270 can be automaticallyconnected.

In FIG. 2B, a printer system 205 can include a platform 235, forexample, to move in xy directions. The printer system 205 can include avertical movement module 225 to move the platform in a z direction. Theprinter system 205 can include a printhead module 216, which can beconfigured to support multiple printheads 215. Controllers 245 and 255can be included for controlling the printer 205 and the printheads 215.

An automatic printhead exchanger module 206 can be included. Theautomatic printhead exchanger 206 can support multiple printheads 217.In addition, the exchanger 206 can include an exchange mechanism 282,which can allow placing a printhead 217 from the exchanger 206 to anempty slot 218 in the printhead module 216. The exchange mechanism 282can also allow retrieving an installed printhead 215 from the printheadmodule 216 back to the exchanger 206. Electrical connections 265/275 canallow communication between the system controller 245 with the printheadcontroller 255.

FIG. 2C shows a coupling between a printhead 218 and a printhead module212. Mechanical coupling 221/222 can be used for mechanically couplingthe printhead 218 to the printhead module 212. The mechanical couplingcan include an alignment mechanism for the controller to know theposition of the printhead. The alignment mechanism can be a mechanicalalignment mechanism or an electrical alignment mechanism. Electricalcoupling 231/232 can be used for electrically connecting the printhead218 to the printhead module 212. The electrical coupling 231/232 can bea contact coupling (e.g., through an electrical connector), or a noncontact coupling (e.g., through a wireless connection such as rfid). Theelectrical coupling 231 can be connected to a bus line, which can runfrom the printhead module to the controller module 245. The electricalcoupling 232 can be connected to the controller circuit of theprinthead, such as the controller 255 of the printhead 215.

In some embodiments, the system can include other exchangeablecomponents, such as exchangeable platform supports in the platformmodule.

In some embodiments, light weight system is provided for electricalcommunication, for example, to accommodate the high throughput and rapidmovements of the printheads, e.g., relative movements with respect tothe platform.

FIGS. 3A-3B illustrate a communication system for 3D printer systemsaccording to some embodiments. In FIG. 3A, a controller module 340 cancommunicate with other modules, such as printhead module 310, motionmodule 320, and platform module 330, through wiring 380. Each componentof the modules, e.g., printheads 311 and 312 of the printhead module310, X axis 321, Y axis 322, and Z axis 323 of the motion module 320,and hotbed 331 and alignment 332 of the platform module 330, can beconnected to the controller 340. The connection can be hot swappable,e.g., allowing connecting and disconnecting without power shutoff.Further, the connection can include automatic configurations, allowingthe controller 340 to recognize and appropriately configure the newlyinstalled components. The connection between the controller and thecomponents can include a central distributed bus, such as USB orEthernet bus.

FIG. 3B shows a detailed configuration between components, such asprintheads 315 and a system controller 341. The system controller 341can communicate with the components, such as multiple printheads 315through wiring 381. The printheads 315 can be electrically coupled withthe system controller 341 through coupling 345/355. The coupling 345/355and the wiring 381 can have multiple wires, e.g., n wires, depending onthe number of components 370 in the printheads 315. For example, thewires can include power wires for an extrusion motor, power wires for aheater, power wires for a fan, and communication wires foridentification. The coupling 345/355 can be hot-swappable, e.g.,connecting and disconnecting while the power is on. The controller 341can include an auto-configuration component, allowing the controller 341to recognize the data of the installed components, such as thecharacteristics of the printhead 315, for automatic installation ofappropriate drivers for running the installed components.

In some embodiments, the present invention discloses a 3D printer systemusing a network of independent controllers having serial communicationprotocols. For example, the serial communication can use 2 dedicatedwires for signal communication, thus allow minimum weight for electricalconnection wires. Controller Area Network (CAN) bus can be used in a 3Dprinter system, in which the printer system, and each of the printheadscan have a CAN controller for controlling the peripheral assemblies,such as motors and heaters. Communication between the printer system andthe printheads can be performed by the dedicated two wires for serialcommunication.

FIGS. 4A-4D illustrate a communication system for 4D printer systemsaccording to some embodiments. In FIG. 4A, a controller module 440 cancommunicate with other modules, such as printhead module 410, motionmodule 420, and platform module 430, through a serial bus 480. Eachcomponent of the modules, e.g., printheads 411 and 412 of the printheadmodule 410, X axis 421, Y axis 422, and Z axis 423 of the motion module420, and hotbed 431 and alignment 432 of the platform module 430, can beconnected to the serial bus 480. The connection can be hot swappable,e.g., allowing connecting and disconnecting without power shutoff.Further, the connection can include automatic configurations, allowingthe controller 440 to recognize and appropriately configure the newlyinstalled components. The connection between the controller and thecomponents can include a serial distributed bus, such as CAN bus.

A controller area network (CAN) can be used for reducing the number ofwirings, together with ease of communication between the controller 440and the components, including the multiple interchangeable printheads411, 412. The communication can be performed through a CAN bus 480,which can have two signal wires. In some cases, 4 wires can be used,including two signal wires and two power wires.

FIG. 4B shows a detailed configuration between components, such asprintheads 415 and a printhead module 441. The printhead module 441 cancommunicate with the components, such as multiple printheads 415 throughCAN bus 481. The printheads 415 can be electrically coupled with the CANbus 481 through coupling 445/455. The coupling 445/455 and the CAN bus481 can have multiple wires, e.g., 2 or 4 wires. The coupling 445/455can be hot-swappable, e.g., connecting and disconnecting while the poweris on. The printhead module 441 can include an auto-configurationcomponent, allowing the printhead module 441 to recognize the data ofthe installed components, such as the characteristics of the printhead415, for automatic installation of appropriate drivers for running theinstalled components.

Each component, e.g., printer system and each of the printheads, caninclude a CAN controller, e.g., CAN controller 442 for the printheadmodule and CAN controller 475 for the printhead 415. The printheadcontroller 475 can control the components 470 in the printhead, such asmotors and heaters. The printhead controller 475 can communicate withthe printhead module 441 through electrical connection 445/455, whichcan be coupled to the CAN bus 481, and to the CAN controller 442. TheCAN controller can include a transceiver for communicating with the CANbus. The CAN controller can include a microprocessor for processing thesystem, such as determining information for sending and receiving fromthe CAN transceiver.

In some embodiments, the electrical coupling between a printhead and aprinthead module can be hardwired, e.g., connecting by a manualconnection between electrical connectors. The electrical coupling can bewireless, for example, by infrared communication or by opticalcommunication.

In FIG. 4C, a printhead 416 can be electrically connected to a printheadmodule 442 through a hardwire coupling 446 and 456. For example,connector 446 can include multiple electrical wires 471 connected tocomponents of the printhead 416, such as to a CAN controller in theprinthead 416. Similarly, connector 456 can include multiple electricalwires 461 connected to components of the printhead module 442, such asto a CAN controller in the printhead module 442. Connector 446 can be afemale connector and connector 456 can be a male connector, which can bemated together to form electrical connections.

In FIG. 4D, a printhead 417 can be electrically connected to a printheadmodule 443 through wireless connection 470/480 and 475/485. For example,a connector 447 can include multiple electrical wires connected tocomponents of the printhead 417. The connector 447 can supply the signalto a transmitter/receiver 470, which can wirelessly communicate withother transmitter/receiver through antenna 475. Similarly, connector 457can include multiple electrical wires connected to components of theprinthead module 443. The connector 457 can supply the signal to atransmitter/receiver 480, which can wirelessly communicate with othertransmitter/receiver through antenna 485. For example,transmitter/receiver 470 can transmit signals to antenna 475, which canbe received by antenna 485 and interpreted by transmitter/receiver 480.The wireless communication can allow ease of installation of printheadsto the printhead module.

In some embodiments, the exchangeable components to a system, such as a3D printer system, can include an alignment mechanism. For example, asecond printhead can have an alignment mechanism, so that when installedto the printhead module, can be aligned with the first printhead.Alternatively, the first and second printheads can be aligned with theprinthead module.

FIGS. 5A-5D illustrate alignment configurations for printheads accordingto some embodiments. In FIG. 5A, a first printhead 510 can be installedin a printhead module 560, such as permanently installed, e.g., not anexchangeable printhead. A second printhead 550 can be exchangeablyinstalled in the printhead module 560. Mechanical coupling 520/525 canbe used to secure the second printhead 550 to the printhead module 560.Electrical coupling 540/545 can be used to provide communication betweenthe printhead module 560 (e.g., and also the system controller module)and the second printhead 550. The second printhead 550 can be aligned tothe first printhead 510, e.g., separating from the first printhead aknown distance 570. The alignment distance 570 can allow the system toprint using the second printhead, e.g., by adding an offset distanceequaled to the alignment distance 570, to the movements for the secondprinthead 550, as compared to the first printhead 510.

In FIG. 5B, a printhead 551 can be exchangeably installed in theprinthead module 561. Mechanical coupling 521/526 can be used to securethe second printhead 551 to the printhead module 561. Electricalcoupling 541/546 can be used to provide communication between theprinthead module 561 (e.g., and also the system controller module) andthe second printhead 551. The printhead 551 can be aligned to theprinthead module 561, e.g., separating from a fixed point in theprinthead module a known distance 571. The alignment distance 571 canallow the system to print using the printhead, e.g., by adding an offsetdistance equaled to the alignment distance 57, to the movements for theprinthead 551.

The alignment distance can be determined by an alignment mechanism, suchas mechanical alignment mechanism or an electrical alignment mechanism.FIG. 5C shows a mechanical alignment mechanism for a printhead 552,establishing an alignment distance 575 to a fixed point in a printheadmodule 562. An attaching mechanism 580, such as a bolt mechanism, cansecure the printhead 552 against a fixed surface of the printhead module562, forming an alignment distance 575. The printhead 552 can includecontrol circuitry 537, which is electrically coupled to a connector 547.The electrical connector 547 can be coupled to another connector 542,which is placed in the printhead module 562. For example, the connector542 in the printhead module can be coupled to a CAN bus, thus allowingthe printhead 552 to be connected to the CAN bus network.

FIG. 5D shows an electrical alignment mechanism for a printhead 553,establishing an alignment distance 577 to a fixed point in a printheadmodule 563. A distance sensor mechanism 581/582, such as an ultrasonicdistance sensor module, can detect a distance 576 from the printhead 553to the printhead module 563. The alignment distance 577 can bedetermined from the distance 576. The printhead 553 can include controlcircuitry 538, which is electrically coupled to a connector 548. Theelectrical connector 548 can be coupled to another connector 543, whichis placed in the printhead module 563. For example, the connector 543 inthe printhead module can be coupled to a CAN bus, thus allowing theprinthead 553 to be connected to the CAN bus network.

In some embodiments, the present invention discloses methods for using amodular system, such as a 3D printer system having exchangeableprintheads and/or exchangeable platform supports. Different printheadsand platform supports can be selected based on the requirements of thejob, and then installed in the system for processing a workpiece.

A modular printer system can be formed by coupling a printhead module toa 3D printer. The printhead module can be configured to accept one ormore printheads that can be removed and exchanged from the printheadmodule. The installation of the printheads to the printhead module caninclude physical and electrical connections, together with signalcommunication, allowing the printer system to control the printheadsassembled in the printhead module. Controller area network connectioncan be used, providing a light weight network communication between themodular printheads and the printer system. The communication can beestablished by 2 wire connectivity, for example, by the communicationprotocol of CAN bus.

A modular printer system can be formed by forming a platform for a 3Dprinter. A printhead module that is configured to accept one or moreprintheads can be formed. A movement mechanism can be formed, whereinthe movement mechanism couples the platform with the printhead module toallow the one or more printheads to print a 3D structure on theplatform.

A modular printer system can be operated by changing a printhead in aprinthead module, with the printhead module automatically configured toaccept the printhead for operation. The automatic configuration canallow the printer system to continue printing with a new installedprinthead right after the printhead is installed, either manually by anoperator or automatically by a printhead exchange module.

A modular printer system can be operated by printing an object using afirst printhead in a printhead module of a 3D printer. A secondprinthead can be added to the printhead module, wherein the secondprinthead is automatically accepted by the printhead module. The systemcan continue to print using the second printhead.

FIGS. 6A-6B illustrate methods to operate a modular printing systemaccording to some embodiments. In FIG. 6A, operation 600 provides asystem for forming a workpiece, wherein the system comprises a platformmodule for supporting the workpiece, a head module configured to supportone or more heads for processing the workpiece, and a 3D motion modulefor moving the head module with respect to the platform module. The headmodule can be a printhead module for supporting printheads. The headmodule can support other heads, such as a head including a pen forplotting, a head including a drill bit for drilling, a head including alaser for cutting, and a head including a cutting bit for cutting suchas milling. The head module can have permanently installed heads, suchas a 3D printhead.

Operation 610 installs or exchanges a first head to the head module. Forexample, the first head can be installed to the head module.Alternatively, an existing head can be removed, and the first head canbe installed to the position vacated by the existing head. Theinstallation or exchange can be performed manually by an operator, orautomatically using a head exchanger module. Mechanically interfaces canbe included for mating the heads to the head module. Additional headscan be installed. Operation 620 electrically configures the first headto be recognized by the system. For example, electrical connectors canbe used for electrically coupling the head to the head module. Wirelessconnection can also be used. Hot-swappable bus can be used, to allowhead installation without shutting power. CAN bus can be used forsimplifying the system electrical connection.

Operation 630 aligns the first head to be recognized by the system. Thealignment can be performed by a mechanical mechanism or by an electricalmechanism. The alignment can allow the system to use the installed head.

In FIG. 6B, operation 640 provides a system for forming a workpiece,wherein the system comprises a platform module for supporting theworkpiece, a head module configured to support one or more heads forprocessing the workpiece, and a 3D motion module for moving the headmodule with respect to the platform module. Operation 660 determines oneor more heads to meet a requirement of processing the workpiece.Operation 670 installs or exchanges heads to the head module. The headscan be configured manually or automatically.

In some embodiments, an operator can prepare the system before runningthe job. Multiple heads can be selected, and installed in the system.The job can be stated, with all the needed heads included in the headmodule.

In some embodiments, the needed heads can be automatically retrievedfrom a head exchanger. Thus an operator can check to make sure that thehead exchanger contains all the needed heads. New heads can be added tothe head exchanger. The job can be stated, with all the needed headsincluded in the head exchanger.

In some embodiments, the present invention discloses a modular system,including a base system together with multiple exchangeable heads suchas printheads, and/or multiple exchangeable platform supports. Themodular system can include a 3D printer system for printing a wokpiece.The 3D printer system can include a printhead module, one or moreprintheads, a platform module, a motion module, and a controller module.The printhead module can include first mechanical interfaces and firstelectrical interfaces for coupling with the one or more printheads. Theprintheads can include second mechanical interfaces and secondelectrical interfaces for coupling with the printhead module. The firstand second mechanical interfaces can be configured to be mated with eachother. The first and second electrical interfaces can be configured tobe connected with each other. The one or more printheads can beconfigured to be exchangeably installed in the printhead module throughthe first and second mechanical and electrical interfaces. The firstprinthead of the one or more printheads can be installed in theprinthead module. The platform module can be configured to support theworkpiece. The motion module can be configured to move the printheadmodule in three dimensional directions relative to the platform module.The controller module can be configured to accept the first printhead.

The first and second mechanical interfaces comprise an alignmentmechanism for aligning a printhead to the printhead module. The firstand second electrical interfaces comprise a contact coupling mechanismfor electrically connecting a printhead to the printhead module. Thefirst and second electrical interfaces comprise a non-contact couplingmechanism for electrically connecting a printhead to the printheadmodule. The first and second mechanical interfaces are configured to bemanually coupled by an operator. The first and second mechanicalinterfaces are configured to be automatically coupled by an automaticcoupling mechanism. The first and second electrical interfaces areconfigured to be manually coupled by an operator. The controller isconfigured to automatically configuring the first printhead foroperation. The first and second electrical interfaces are configured tobe hot-swappable.

In some embodiments, the 3D printer system can include an electricalalignment circuit coupled to at least one of the printhead module and aprinthead, wherein the electrical alignment circuit is configured toprovide alignment information for aligning the printhead to theprinthead module. The 3D printer system can include an automaticprinthead exchanger mechanism, wherein the automatic printhead exchangermechanism is configured to automatically exchange a printhead in theprinthead module. The 3D printer system can include a serial bus,wherein the serial bus is coupled to the first electrical interfaces,wherein the serial bus is coupled to the controller module. The 3Dprinter system can include a bus line, wherein the bus line is coupledto the first electrical interfaces, wherein the bus line is coupled tothe controller module.

In some embodiments, the 3D printer system can include one or moreworkpiece supports. The platform module comprises third electricalinterfaces for coupling with the one or more workpiece supports. Theworkpiece supports comprise fourth electrical interfaces for couplingwith the platform module. The third and fourth electrical interfaces areconfigured to be connected with each other. The one or more workpiecesupports are configured to be exchangeably installed in the platformmodule through the third and fourth electrical interfaces. The firstworkpiece support of the one or more workpiece supports is installed inthe platform module.

In some embodiments, the present invention discloses a system, includinga printhead module; wherein the printhead module comprises firstmechanical interfaces and first electrical interfaces for coupling withone or more printheads, wherein the one or more printheads areconfigured to be exchangeably installed in the printhead module throughthe first mechanical and electrical interfaces; a platform module,wherein the platform module is configured to support a workpiece; amotion module, wherein the motion module is configured to move theprinthead module in three dimensional directions relative to theplatform module; a controller module, wherein the controller modulecomprises a controlled area network bus (CAN bus), wherein the CAN busis coupled to the first electrical interfaces; wherein the controllermodule is configured to automatically configured a printhead of the oneor more printheads installed in the printhead module through the CANbus. The first electrical interfaces can include a CAN node coupled tothe CAN bus. The second electrical interfaces can include a CAN node forcoupling to the CAN bus through the first electrical interfaces. The CANnode can include a controller having information related toconfigurations of the printheads.

In some embodiments, the present invention discloses a system, includinga printhead module; one or more printheads, wherein the printhead modulecomprises first mechanical interfaces and first electrical interfacesfor coupling with the one or more printheads, wherein the printheadscomprise second mechanical interfaces and second electrical interfacesfor coupling with the printhead module, wherein the first and secondmechanical interfaces are configured to be mated with each other,wherein the first and second electrical interfaces are configured to beconnected with each other, wherein the one or more printheads areconfigured to be exchangeably installed in the printhead module throughthe first and second mechanical and electrical interfaces, wherein afirst printhead of the one or more printheads is installed in theprinthead module; a platform module, wherein the platform module isconfigured to support a workpiece; a motion module, wherein the motionmodule is configured to move the printhead module in three dimensionaldirections relative to the platform module; a controller module, whereinthe controller module comprises a controlled area network bus (CAN bus),wherein the CAN bus is coupled to the first electrical interfaces;wherein the controller module is configured to automatically configuredthe first printhead through the CAN bus.

In some embodiments, the present invention discloses multiple printheadsfor 3D printing, which can be exchangeably installed in a base system ofa 3D printer system. For example, the printheads can include filamentextruder heads with different diameters and different configurations.The term 3D printer system can include mechanisms for additivemanufacturing, together with other technologies, such as subtractivemanufacturing with drilling, milling and lathing, and laser cutting andwriting and droplet printing.

FIGS. 7A-7D illustrate printhead configurations according to someembodiments. FIG. 7A shows a schematic of a filament extruded printhead,accepting a filament 754 to a printhead nozzle 710. A heater 751 can beincluded to heat the printhead nozzle to a temperature that can melt orsoften the filament 754. A thermocouple or a thermistor 750 can becoupled to the printhead nozzle to monitor the temperature of theprinthead nozzle. A motor 752 can be used to push the filament 754 intothe printhead nozzle 710. An additional element 753, such as a fan, canbe included. The printhead can include a mechanical coupling 725, whichis attached to a printhead body 720. The mechanical coupling 725 can beused to mechanically couple the printhead to a printhead module. Theprinthead can include a circuit board 740, which includes an electricalcoupling 745 for electrical connecting to the printhead module.

In some embodiments, a printhead can be coupled to a cooling mechanism,such as a cooling fan. The cooling mechanism can be operable to cool thesubstrate, or to cool the material being printed. The cooling mechanismcan be configured to present minimum interference to the heatedprinthead. For example, the cooling mechanism can be configured todeliver a focused beam of gas, e.g., air, to an area just a little awayfrom the printhead nozzle. The focused beam of gas can be a confinedbeam, which can provide a gas flow to the material delivered from theprinthead or to the material deposited on the platform surface. Thefocused or confined beam of gas can cool the printed material without(or with minimum) cooling the heated portion of the printhead.

FIG. 7B shows a filament extruded printhead, which can accept a filament754* to a printhead nozzle 710*. A heater 751 can be included to heatthe printhead nozzle to a temperature that can melt or soften thefilament 754*. A thermocouple or a thermistor 750 can be coupled to theprinthead nozzle to monitor the temperature of the printhead nozzle. Amotor 752* can be used to push the filament 754* into the printheadnozzle 710*. A fan 753* can be included. The printhead can include amechanical coupling 725* to mechanically couple the printhead to aprinthead module. The printhead can include an electrical coupling 745*for electrical connecting to the printhead module.

The cooling fan can be configured to deliver a confined or focused gasflow, such as air flow, to an area away from the outlet of the printheadnozzle, such as to a material just coming out of the printhead, or to amaterial just deposited on a substrate, or to a substrate area that theprinthead is to be deposited a printed material. The confined or focusedgas flow can be configured to avoid the printhead, such as the heatedportion of the printhead. Shielding mechanism, such as a flow diverteror flow blockage, can be provided between the cooling fan and theprinthead, for example, to prevent the gas flow from cooling the heatedprinthead and to confine or focus the gas flow to the substrate or tothe printed material. A blower with a flow focus mechanism can be used.

FIG. 7C shows a filament extruded printhead with a tilted nozzle. Aprinthead 711 can have a nozzle 771 that forms an angle 781 with thevertical direction, as compared to a vertical nozzle as in previousfigures. Other components can be included, such as a motor (not show),heater 756, and temperature measurement element 730. The printhead caninclude a mechanical coupling 721 to mechanically couple the printheadto a printhead module. The printhead can include an electrical coupling741 for electrical connecting to the printhead module.

FIG. 7D shows a filament extruded printhead with a tilted nozzletogether with a fan for cooling the extruded filament. The tilted nozzlecan be configured to print a tilted line, thus might need to be quicklycooled, for example, by the fan. A printhead 712 can have a nozzle 773that forms an angle with the vertical direction. Other components can beincluded, such as a motor (not show), heater 757 for heating theprinthead body 712, heater 773 for heating the tilted nozzle 772,temperature measurement element 731, and fan 774 directed toward theextruded filament. The printhead can include a mechanical coupling 722to mechanically couple the printhead to a printhead module. Theprinthead can include an electrical coupling 742 for electricalconnecting to the printhead module.

FIGS. 8A-8D illustrate printhead configurations according to someembodiments. FIG. 8A shows a schematic of a filament extruded printhead,which can accept a filament 835 to a printhead nozzle 810. A heater canbe included to heat the printhead nozzle to a temperature that can meltor soften the filament. A thermocouple or a thermistor can be coupled tothe printhead nozzle to monitor the temperature of the printhead nozzle.A motor 830 can be used to push the filament 835 into the printheadnozzle 810. An additional element 860, such as a blower and/or a vacuumpump, can be included to clean debris generated by the motor pressing onthe filament. The printhead can include a mechanical coupling 820, whichis attached to a printhead body. The mechanical coupling 820 can be usedto mechanically couple the printhead to a printhead module. Theprinthead can include an electrical coupling 840 for electricalconnecting to the printhead module.

FIG. 8B shows a schematic of a filament extruded printhead, which caninclude an agitation element 861 for vibrating the filament in aprinthead nozzle 811. The printhead can include a mechanical coupling821, which can be used to mechanically couple the printhead to aprinthead module. The printhead can include an electrical coupling 841for electrical connecting to the printhead module.

FIG. 8C shows a schematic of a filament extruded printhead, which caninclude a lamp 862 for providing a light 872, such as an IR or an UVlight to the extruded filament in a printhead nozzle 812. The printheadcan include a mechanical coupling 822, which can be used to mechanicallycouple the printhead to a printhead module. The printhead can include anelectrical coupling 842 for electrical connecting to the printheadmodule.

FIG. 8C shows a schematic of a filament extruded printhead, which caninclude a laser 863 for providing a laser beam 873 to the extrudedfilament in a printhead nozzle 813. The printhead can include amechanical coupling 823, which can be used to mechanically couple theprinthead to a printhead module. The printhead can include an electricalcoupling 843 for electrical connecting to the printhead module.

FIGS. 9A-9D illustrate printhead configurations according to someembodiments. FIG. 9A shows a schematic of a filament extruded printhead,which can accept multiple filaments 930 and 932 to a printhead nozzle910. A heater 935 can be included to heat the printhead nozzle to atemperature that can melt or soften the filament. A thermocouple or athermistor can be coupled to the printhead nozzle to monitor thetemperature of the printhead nozzle. Multiple motors can be used to pushthe filaments into the printhead nozzle 910. The printhead can include amechanical coupling 920, which is attached to a printhead body. Themechanical coupling 920 can be used to mechanically couple the printheadto a printhead module. The printhead can include an electrical coupling940 for electrical connecting to the printhead module.

FIG. 9B shows a schematic of a paste extruding printhead, which canaccept a paste like material 951 to a printhead nozzle 911. A heater 952can be included to heat the printhead nozzle. A plunger 950 can be usedto push the paste 951 into the printhead nozzle 910. The printhead caninclude a mechanical coupling 921, which can be used to mechanicallycouple the printhead to a printhead module. The printhead can include anelectrical coupling 941 for electrical connecting to the printheadmodule.

FIG. 9C shows a schematic of a liquid extruding printhead, which canaccept a liquid 961 from a reservoir 960 to a printhead nozzle 912. Aheater 963 can be included to heat the printhead nozzle. A motor 962 canbe used to push the liquid into the printhead nozzle 912. The printheadcan include a mechanical coupling 922, which can be used to mechanicallycouple the printhead to a printhead module. The printhead can include anelectrical coupling 942 for electrical connecting to the printheadmodule.

Other printhead configurations can be included, which can be used forcutting, painting, and milling, instead of printing.

FIGS. 10A-10D illustrate printhead configurations according to someembodiments. FIG. 10A shows a laser cutter head, which includes a laserassembly 1010 for emitting a laser beam 1050. The printhead can be usedfor cutting materials off a workpiece. The printhead can include amechanical coupling 1020, which can be used to mechanically couple theprinthead to a printhead module. The printhead can include an electricalcoupling 1040 for electrical connecting to the printhead module.

FIG. 10B shows a computer numerical control (CNC) head, which includes aholder assembly 1011 for supporting a CNC bit 1051, such as a drill bitor a mill bit. The printhead can be used for milling or cuttingmaterials off a workpiece. The printhead can include a mechanicalcoupling 1021, which can be used to mechanically couple the printhead toa printhead module. The printhead can include an electrical coupling1041 for electrical connecting to the printhead module.

FIG. 10C shows an inkjet head, which includes an inkjet 1012 foremitting droplets 1070 of liquid, for example, for printing. Theprinthead can be used for printing on a workpiece. The printhead caninclude a mechanical coupling 1022, which can be used to mechanicallycouple the printhead to a printhead module. The printhead can include anelectrical coupling 1042 for electrical connecting to the printheadmodule.

FIG. 10D shows a pen plotter head, which includes a holder assembly 1013for supporting a pen 1080. The printhead can be used for writing on aworkpiece. The printhead can include a mechanical coupling 1023, whichcan be used to mechanically couple the printhead to a printhead module.The printhead can include an electrical coupling 1043 for electricalconnecting to the printhead module.

In some embodiments, the present invention discloses multiple platformsfor 3D printing, which can be exchangeably installed in a base system ofa 3D printer system. For example, the platforms can include horizontalplatforms, vertical platforms, platforms with watermarks, and clampingplatforms.

FIGS. 11A-11D illustrate platform configurations in a modular systemaccording to some embodiments. FIG. 11A shows a horizontal flat platformconfiguration, which can include a platform 1130 for supporting aprinted material 1150 from a 3D printhead 1110. A heater 1120 can beused to heat the platform 1130. A mechanical coupling and an electricalcoupling can be included to mechanically and electrically couple theplatform to a base system, such as a 3D printer system with exchangeableplatform.

FIG. 11B shows a horizontal flat platform configuration with awatermark, which can include a platform 1131 for supporting printedmaterials. Watermark 1160 can be formed on a surface of the platform1131. A heater 1121 can be used to heat the platform 1131. A mechanicalcoupling and an electrical coupling can be included to mechanically andelectrically couple the platform to a base system, such as a 3D printersystem with exchangeable platform.

FIG. 11C shows a flat platform configuration, which can include ahorizontal platform 1132 and a vertical platform 1133. The verticalplatform can be used for supporting printed materials from a tiltednozzle 1142 of a printhead 1112. Optional watermarks 1161 and 1162 canbe included on the surfaces of the platforms 1132 and 1133. Heaters 1121and 1122 can be used to heat the platforms 1132 and 1133. A mechanicalcoupling and an electrical coupling can be included to mechanically andelectrically couple the platform to a base system, such as a 3D printersystem with exchangeable platform.

FIG. 11D shows a clamp platform configuration, which can include a clampmechanism 1123 for clamping on a workpiece 1151. A printhead 1113 can beused to print on a surface, e.g., the top flat surface, of the workpiece1151. The clamp platform can be used for supporting existing workpiece,e.g., for the printhead 1113 to print on a surface of an existingworkpiece. The clamping platform can support irregular workpiece,together with supporting large workpiece, since a portion of theworkpiece can be placed outside of the printable area. A mechanicalcoupling and an electrical coupling can be included to mechanically andelectrically couple the platform to a base system, such as a 3D printersystem with exchangeable platform.

In some embodiments, the present invention discloses printheads for usedin a system, such as a 3D printer system. The printheads can be useddirectly in the system. The printheads can have a mechanical interfaceand an electrical interface to be used in a modular system, e.g., asexchangeably printheads in a printhead module of a 3D printer system.The interfaces can be configured to be mated with a printhead module,e.g., one or more printheads can be installed in a printhead module withmated mechanical and electrical interfaces. Serial bus, such as CAN bus,can be used for electrical communication between the printheads and theprinthead module (and also the 3D printer system). The printheads caninclude information to allow automatic configuration, e.g., theprinthead can send information related to the printhead physicalcharacteristics and functionalities, so that a system controller cancontrol the printheads.

The modular system can thus be configured for different job requirementsby selecting the printheads suitable for the job. The selection can beperformed manually by an operator, or can be performed automatically,for example, through a printhead exchange module. In the presentspecification, the printheads can be shown with or without theinterfaces with a printhead module. However, it is understood thatinterfaces are implied, and thus an exchangeable printhead can have bothmechanical and electrical interfaces for mating with the printheadmodule.

In some embodiments, the printheads can be used independently, e.g.,without the mechanical and/or electrical interfaces. A printhead can beused in a 3D printer system, e.g., secured to the 3D printer systemwithout the removable interfaces.

In some embodiments, the present invention discloses printheads having anozzle outlet with different shapes. The nozzle can deliver materialshaving different cross sections, such as round, oval, rectangular, orcross, with different dimensions. For example, cross pattern can createtie points that go through the build plate. The cross pattern can reducethe lift off problem in which the plastic bungs that go through thebuild plate would shear off easily with a razor blade.

FIGS. 12A-12B illustrate printheads having different nozzle patternsaccording to some embodiments. In FIG. 12A, a printhead 1210 can includea heater 1215 for heating the material delivered to the printhead.Printing material, such as plastic filament 1230, can be driven into theprinthead by a rotating gear mechanism 1220. At the heated printhead1210, the plastic filament 1230 can be melted to become molten plastic1235. The molten plastic 1235 can be driven out of the printhead, forexample, through a nozzle at the end of the printhead. The material1240, out of the printhead, can be deposited on a heated platform. Theprinthead can include a mechanical interface 1225 and an electricalinterface 1245.

FIG. 12B shows various cross sections AA′ of the printed material 1240,generated by different nozzles at the end of the printhead. The crosssection of the material 1240 can be circular 1241, oval 1242, rectangle1243, or cross 1244. In some embodiments, the cross pattern 1244 can beused on top of each other 1251, or offset from each other 1252 or 1253.The nozzles can generate materials having cross section with varioussizes and dimensions, as shown, for example, in different circles 1241A,1241B, and 1241C with different diameters.

In some embodiments, different types of filaments can be installed inthe printheads, so that the printer system can be configured to printdifferent materials. Similarly, filaments with different colors can alsobe installed in the printheads, so that the printer system can beconfigured to print different colors.

In some embodiments, the present invention discloses 3D printer systemsand methods that can form overhang features without a temporary supportstructure. The systems can include a print head having a nozzle thatforms an angle with the support surface. For example, in a linear xyzprinter system, the print head can move in a vertical z direction, e.g.,up and down from the support table. The support table can move inhorizontal x and y directions. Thus multiple xy plane layers can beformed on each other in the z direction to form the 3D printed object.In some embodiments, the nozzle can form an angle with the vertical zdirection, e.g., forming an angle with the normal direction of thesupport table.

FIG. 13 illustrates 3D printer systems and printheads according to someembodiments. A print head can include an extrusion head 1310 having aheater 1315 for heating the extruded material that is supplied to theextrusion head 1310. A nozzle 1340 can be coupled to the extrusion head1310, having a nozzle that forms an angle 1345 with the support table1330. A heater 1335 can be couple to the support table 1330 for heatingthe table surface. The printhead can include a mechanical interface andan electrical interface (not shown), to be installed exchangeably in aprinthead module of the 3D printer system.

The nozzle 1340 and the extrusion head 1310 can be coupled together withthe heater 1315 heating the material in the extrusion head.Alternatively, the nozzle and the extrusion head can form an integratedhead, for example, the heater 1315 can head the material in both theextrusion head and the nozzle.

The print head can be moved in a vertical direction to form a verticalwall 1320. For example, a first line can be formed, followed by a secondline directly disposed on the first line. The lines can be directlyplaced on top of each other to form a vertical wall 1320.

The print head can be moved in a horizontal direction to form ahorizontal wall 1360, e.g., an overhang feature. Due to the anglednozzle, horizontal lines can be bonded to each other to form thehorizontal wall 1360. Walls having other angles can also be printed withthe angled nozzle.

FIGS. 14A-14F show different print head nozzles. The printhead caninclude a mechanical interface and an electrical interface (not shown),to be installed exchangeably in a printhead module of the 3D printersystem. A print head 1410 can have a nozzle 1441 forming an acute angle1451, e.g., less than 90 degrees or less than 45 degrees, with thesupport platform, e.g., with the normal direction of the platform (FIG.14A). The print head can have a nozzle 1442 forming a 45 degree angle1452 with the support platform (FIG. 14B). The print head can have anozzle 1443 forming an angle 1453 of less than 90 degrees with thesupport platform (FIG. 14C).

The print head can have a nozzle 1444 forming a square angle 1454, e.g.,perpendicular to the support platform or parallel to the surface of theplatform (FIG. 14D). The print head can have a nozzle 1445 or 1446forming obtuse angle 1455 or 1456, e.g., greater than 90 degrees, withthe support platform (FIG. 14E showing an angle between 90 and 145degrees, and FIG. 14F showing an angle of about 145 degrees).

In some embodiments, the nozzle can form an angle between 30 and 150degrees, e.g., the nozzle can be downward or downward pointing with anangle greater than 30 degrees. In some embodiments, the nozzle can forman angle between 45 and 145 degrees. In some embodiments, the nozzle canform an angle between 45 and 90 degrees.

FIGS. 15A-15D illustrate a schematic mechanism for forming overhangfeatures without support structures according to some embodiments. Insome embodiments, a nozzle 1510 pointed to a vertical direction canaccept a material 1515. The material 1515 can be pushed along thedirection 1516, for example, through a screw head, of the nozzle 1510,e.g., extruding on the surface of the object. In FIG. 15A, the nozzlehead 1510 can be directly positioned on previously deposited lines toform a vertical wall, e.g., by moving the nozzle 1510 in the direction1512 along the length of the lines. When the newly extruded material ispushed from the nozzle, a perpendicular force 1517 can be exerted, whichcan be in a same direction as the pushing direction 1516 of the extrudedmaterial. The force 1517 can cause the new material to adhere to theexisting material, forming a solid vertical wall.

In FIG. 15B, the nozzle head 1510 can form an angle 1553 with thepreviously deposited lines to form a titled wall. When the newlyextruded material is pushed from the nozzle, a perpendicular force 1517can be exerted, which can be in a same direction as the pushingdirection of the extruded material. The force 1517 can have a component1518 that cause the new material to adhere to the existing material. Ifthe angle 1553 is large, for example, greater than 90 degrees, theadhesion force component 1518 is zero, and thus the new deposited linedoes not adhere to the previous lines. In general, an angle of less than45 or less than 30 degrees can be used, with smaller angle resulting inbetter adhesion of the printed lines, e.g., non collapsed overhangfeatures.

In some embodiments, the nozzle can form an angle with the supportplatform. A nozzle 1520 pointed to any direction can accept a material1525. The material 1525 can be pushed along the direction 1526 of thenozzle 1520, e.g., extruding on the surface of the object. In FIG. 15C,the nozzle head 1520 can be horizontal, e.g., pointed to a horizontaldirection. The nozzle can deliver material directly on previouslydeposited horizontal lines to form a horizontal wall, e.g., by movingthe nozzle 1520 in the direction 1522 along the length of the lines.When the newly extruded material is pushed from the nozzle, aperpendicular force 1527 can be exerted, which can be in a samedirection as the pushing direction 1526 of the extruded material. Theforce 1527 can cause the new material to adhere to the existingmaterial, forming a solid horizontal wall.

In FIG. 15D, the nozzle head 1520 can form an angle 1563 with thepreviously deposited lines to form a titled wall. When the newlyextruded material is pushed from the nozzle, a perpendicular force 1527can be exerted, which can be in a same direction as the pushingdirection of the extruded material. The force 1527 can have a component1528 that cause the new material to adhere to the existing material. Ifthe angle 1553 is large, for example, greater than 90 degrees, theadhesion force component 1528 is zero, and thus the new deposited linedoes not adhere to the previous lines. In general, an angle of less than45 or less than 30 degrees can be used, with smaller angle resulting inbetter adhesion of the printed lines, e.g., non collapsed overhangfeatures.

In some embodiments, a nozzle can print an overhang feature of less than45 or less than 30 degrees with respect to the printing direction of thenozzle. Thus a vertical nozzle, e.g., a nozzle perpendicular to thesupport surface can form overhang structure at angles less than 45 or 30degrees. The angle can also depend on the size of the overhang. Forexample, a short overhang of less than a few millimeters, e.g., lessthan 10 or less than 5 mm, can be printed with large overhang angles,e.g., less than 45 degrees. Longer overhang features of centimeter size,e.g., less than 10 or less than 5 cm, can be printed with smalleroverhang angles such as less than 30, 20 or less than 10 degrees.

In some embodiments, the present invention discloses a print head havingnozzle forming an angle with the normal direction of the supportsurface. The angled nozzle can allow printing overhang with higherangles for long overhang features. For example, a nozzle having a tiltedangle of 45 degrees can print very long overhangs that form 30 to 70degrees, or long overhangs that form 15 to 85 degrees. Other tiltedangles can be used, such as 90 degree tilted nozzle, which can printoverhangs of 75 to 105 degrees. In some embodiments, a mechanism can beprovided to adjust the angle of the nozzle, allowing printing differentangle overhangs.

In FIG. 16A, a tilted nozzle can print an overhang feature 1620 having asame tilted angle. For example, if the nozzle is tilted 60 degrees,e.g., forming 60 degrees with the support surface, the nozzle can printan overhang tilted 60 degrees.

In FIGS. 16B and 16C, the nozzle can also print an overhang with anangle offset from the tilted angle of the nozzle. The overhang 1622 canhave a downward offset angle 1632, e.g., clockwise or negative angle.The overhang 1624 can have an upward offset angle 1634, e.g.,counterclockwise or positive angle. The offset angle 1632 can be largerthan the offset angle 1634 due to gravitational force. For example, thetilted nozzle can always print a vertical wall regardless of the tiltedangle of the nozzle, since the printed lines are assisted by gravity toadhere to each other.

FIGS. 17A-17B illustrate a printing process of a horizontal overhangaccording to some embodiments. FIG. 17A shows a top view and FIG. 17Bshows a cross section view. A tilted nozzle 1710 having 90 degree tiltedangle can be used to print horizontal overhang feature such as ahorizontal surface. The tilted nozzle 1710 can be used to print verticalsurface 1730, for example, by moving in multiple circles. At the top ofthe vertical surface, the horizontal surface 1720 can be printed. Theadhesion of the horizontal wall can be provided through the extrudedforce through the nozzle.

In some embodiments, the nozzle is configured to be movable, such asrotating around the print head axis through the control of a controller.The controllable rotatable nozzle can allow printing materials atdifferent directions, such as horizontal circular lines to form ahorizontal overhang surface of a cylinder. The nozzle can be rotatablewhile the print head is stationary, or both nozzle and print head arerotatable, with respect to a feature coupled to a movement mechanism formoving the print head.

FIGS. 18A-18B illustrate rotatable nozzles according to someembodiments. In FIG. 18A, a nozzle 1840 can be coupled to a print head1810 through a rotatable seal 1877. A motor 1870 can be coupled to theprint head 1810. The motor 1870 can be operable to rotate the nozzle1840 through the axis 1830 of the print head, for example, by a belt1875. In FIG. 18B, a nozzle 1845 can be coupled to a print head 1815through a rotatable seal 1878. A motor 1871 can be coupled to the printhead 1815. The motor 1871 can be operable to rotate the nozzle 1845through the axis of the print head, for example, by a belt 1876.

In some embodiments, the nozzle is configured to be movable with respectto the tilted angle, such as rotating to change the tilted angle of thenozzle. The movement can be manually, or can be controlled by acontroller. The adjustable tilted nozzle can allow printing overhangfeatures having different overhang angles. The nozzle angle can becontinuously adjustable, e.g., rotatable through a motor, or can beincrementally adjustable, e.g., rotatable through a pneumatic orhydraulic cylinder.

FIGS. 19A-19B illustrate rotatable nozzles according to someembodiments. In FIG. 19A, a nozzle 1940 can be coupled to a print head1910 through a rotatable seal 1977. A motor 1970 can be coupled to theprint head 1910. The motor 1970 can be operable to rotate the nozzle1940, for example, by a belt 1975, to change the tilted angle of thenozzle. In FIG. 19B, a nozzle 1945 can be coupled to a print head 1915.A linear mechanism, e.g., a cylinder 1971, a linear motor or any linearmovement mechanism, can be coupled to the print head 1915. The cylinder1971 can be operable to rotate the nozzle angle, e.g., changing theangle of the nozzle by extending or contracting the cylinder.

The nozzle or print head can additional be rotatable from an axis of theprint head. For example, a nozzle 1945 can be coupled to a supportfeature 1910 through a rotatable seal 1988. A motor 1981 can be coupledto the print head 1915. The motor 1981 can be operable to rotate thenozzle 1945 through the axis of the print head, for example, by a belt1986.

In some embodiments, the nozzle can be remotely heated, e.g., thematerials inside the nozzle can be heated by a wireless mechanism, suchas an infrared heater or an inductive coupled heater. The material canbe heated in the extruder head, and then can be pushed through thenozzle to the support table. The nozzle can be heated, for example, toprevent the material from solidifying. Since the nozzle is movable, awireless heater can be used.

FIGS. 20A-20B illustrate printheads having remote heaters for the nozzleaccording to some embodiments. A rotatable nozzle 2040 can be coupled toa print head 2010 through a seal 2077. In FIG. 20A, a heater 2015 can beused to heat the print head 2010. Heater 2050 can be used to heat thenozzle 2040. Heater 2050 can be an inductive coupled heater, which canallow the nozzle 2040 to move freely. In FIG. 20B, infrared lamp heatercan be used to heat the nozzle and print head. For example, an IR heater2023 can be used to heat the print head 2010. An IR heater 2055 can beused to heat the nozzle 2040.

FIGS. 21A-21B illustrate flow charts for operating print heads having atilted nozzle according to some embodiments. The tilted nozzle can havea fixed tilted angle. In FIG. 21A, operation 2100 provides a nozzlecoupled to a 3D print head. The nozzle forms an angle with an axis ofthe print head. For example, the print head can be pointed to a printingsurface. The nozzle can form an angle with the pointed direction of theprint head. In some embodiments, the nozzle is configured to deliver amaterial in a direction that forms an angle with a support structure.For example, the support structure can be in an xy plane, and the nozzlecan form an angle with the z direction.

Operation 2110 prints a material on a surface. The nozzle forms anoffset angle with the surface. The offset angle can allow the nozzle toprint overhang features with large angles.

In some embodiments, a nozzle can be provided in a configuration thatforms an angle with the normal direction of a support surface. Thenozzle can deliver material at an angle to the support surface.

In FIG. 21B, operation 2130 rotates a nozzle coupled to a 3D print head.The nozzle is rotated to form an angle with the print head. The nozzlecan be rotated to form an angle with a support surface. The rotation canbe performed by a controller or by a manual operation. Operation 2140prints a material on a surface. The nozzle forms an offset angle withthe surface.

FIGS. 22A-22B illustrate flow charts for operating print heads having atilted nozzle according to some embodiments. The tilted nozzle can havea fixed tilted angle. The nozzle can be rotated around an axis of theprint head, e.g., facing 360 degrees around the print head. In FIG. 22A,the nozzle can print a straight line. The straight line can be ahorizontal line or a vertically tilted line, e.g., an upward or downwardline. Operation 2200 provides a nozzle coupled to a 3D print head. Thenozzle forms an angle with an axis of the print head or a normaldirection of a printing surface. Operation 2210 prints a material on asurface. The nozzle can be configured to face the same direction. Thenozzle can be kept at a constant height, e.g., printing a horizontalline. The nozzle can move in a vertical direction (in addition to ahorizontal direction), e.g., printing a tilted line.

In FIG. 22B, the nozzle can print a curved line. The curved line can bea horizontal line or a vertically tilted line, e.g., an upward ordownward line. Operation 2230 provides a nozzle coupled to a 3D printhead. The nozzle forms an angle with an axis of the print head or anormal direction of a printing surface. The nozzle is configured to facea direction. Operation 2240 prints a material on a surface whilechanging the direction of the nozzle. The nozzle can be kept at aconstant height, e.g., printing a horizontal line. The nozzle can movein a vertical direction (in addition to a horizontal direction), e.g.,printing a tilted line.

FIG. 23 illustrates a 3D printer system having a tilted nozzle and acooling mechanism. A print head can include an extrusion head 2311having an optional heater 2316 for heating the extruded material that issupplied to the extrusion head 2311. A nozzle 2350 can be coupled to theextrusion head 2311, having a nozzle that forms an angle 2355 with asupport table 2330. A heater 2335 can be couple to the support table2330 for heating the table surface.

The nozzle 2350 and the extrusion head 2311 can be coupled together withthe heater 2316 heating the material in the extrusion head.Alternatively, the nozzle and the extrusion head can form an integratedhead, for example, the heater 2316 can head the material in both theextrusion head and the nozzle. Alternatively, optional heater 2316 canhead the material in the printhead and heater 2352 coupled to the nozzlecan heat the material in the nozzle 2350.

The print head can be moved in a vertical direction to form a verticalwall 2321. For example, a first line can be formed, followed by a secondline directly disposed on the first line. The lines can be directlyplaced on top of each other to form a vertical wall 2321. The print headcan be moved in a horizontal direction to form a horizontal wall 2322,e.g., an overhang feature. Due to the angled nozzle, horizontal linescan be bonded to each other to form the horizontal wall 2322. Wallshaving other angles can also be printed with the angled nozzle.

The cooling mechanism, e.g., a cooling fan 2346, can be coupled to theprinthead 2311, for example, to cool the printed material. The coolingfan 2346 can provide a cooling gas flow to the printed material, such asthe overhang 2322, helping to cool the overhang material faster, thuspreventing the overhang from being collapsed, for example, due to thegravitational force pulling the overhang downward, and due to the hightemperature softening the overhang structure.

In some embodiments, the cooling mechanism can be configured to cool theprinted material faster, thus assisting in solidify or strengthening theprinted material and preventing the printed material from beingcollapsed or deformed. The cooling mechanism can be coupled to a tiltednozzle, and can assist in cooling faster an overhang structure.

FIGS. 24A-24C illustrate flow charts for printheads having a coolingmechanism according to some embodiments. In FIG. 24A, a printhead can beformed with a cooling mechanism. Operation 2400 couples a gas source toa 3D printhead. The gas source can be configured to cool printedmaterials with minimum effect on the 3D printhead. The gas source can bea blower with a flow focused mechanism to provide a confined air flow tothe printed material and away from the heated portion of the printhead.

In FIG. 24B, an operation of a printhead can include cooling the printedmaterial after depositing the material. Operation 2420 prints, by a 3Dprinthead, a material on a substrate. Operation 2430 cools the printedmaterial without cooling the 3D printhead.

In FIG. 24C, an operation of a printhead can include cooling a printedoverhang structure with a cooling mechanism right after printing thematerial. Operation 2450 prints, by a 3D printhead having a tiltednozzle, a material on a substrate. The material forms an angle with thesubstrate. Operation 2460 rapidly cools the printed material, forexample, by a cooling mechanism, to secure the printed material to thesubstrate.

In some embodiments, the present invention discloses a 3D printer systemhaving a temperature controlled platform, such as a platform that can beheated or cooled. The heated platform can be operable to assist inheating the printed material, for example, during the printingoperation. The cooled platform can be operable to release the printedobject from the platform, for example, by reducing the adhesion betweenthe printed object and the cooled platform.

In some embodiments, the present invention discloses a printer systemhaving a cleaning mechanism. During a printing process, especially along printing process, debris can be generated, for example, at afilament moving mechanism of the printhead. The debris can interferewith the printing process, leading to less-than-optimum printingconditions or even faulty printing conditions. A cleaning mechanism canremove the debris, maintaining the printer at same printing conditionsduring the long printing process, leading to consistent quality of theprinted object.

In some embodiments, the cleaning mechanism can include a blower fordelivering a gas flow, or a vacuum hose for removing debris. Thecleaning mechanism can be operated continuously, intermittently, orperiodically during the printing process. The cleaning mechanism can beself cleaning, e.g., the blower or the vacuum hose can be configured tobe automatically operated. For example, the blower or the vacuum hosecan be integrated with the printhead, allowing automatic removal ofdebris without operator intervention. Alternatively, the blower or thevacuum hose can be installed at a park location, and the printhead canbe periodically moved to the park location to be cleaned beforereturning to printing.

In some embodiments, the cleaning mechanism can include an exposure ofthe debris generated portion, such as a filament moving mechanism. Theexposure can allow an operator to perform in-situ cleaning of theprinthead, for example, by blowing or vacuum sucking generated debristhat becomes visible through the exposure. The cleaning process can beperformed during printing, or after the printhead moving to a parklocation.

A filament moving mechanism can generate debris in a printhead. Forexample, a printhead can include a filament moving mechanism for movingfilament to an extrusion chamber. The filament moving mechanism caninclude rotating gears, driving solid filament portion to the extrusionchamber, in which the filament is heated to become molten or meltedfilament. The molten or melted filament can be driven out of theprinthead, for example, through a nozzle at the end of the printhead. Aprinthead moving mechanism can be coupled to the printhead to move theprinthead. The material, out of the printhead, can be deposited on aheated platform. The material can form solid 3D object, by a combinationof movement of the printhead and the platform.

In the printhead, debris can be generated at a moving portion, such asat the filament moving mechanism. For example, the gear can be designedto exert a pressure on the filament while moving, with a pressure highenough to move the filament by friction. Further, to provide aconsistent filament moving speed, high friction can be used between thegear and the filament. To enhance friction force, the gear can haveteeth, such as sharp tips at the outer portion of the gear, to avoidslippage of the filament. For example, the sharp tips of the gear canbite into the filament, allowing the filament to move at a linear speedcorresponded to the rotating speed of the gear. The engagement of thegear with the filament can generate debris after a certain operationtime. The debris, if not removed, can affect the operation of theprinthead. For example, the debris can coat the gear, smoothing thegear, and can generate slippage of the filament. The filament slippagecan make the motion of the filament unpredictable, leading to poorprinting conditions.

In some embodiments, the present invention discloses a cleaningmechanism for removing generated debris at a printhead. The cleaningmechanism can be integrated with the printhead for automatic cleaning,e.g., cleaning without an operator, such as in-situ cleaning, e.g.,cleaning during the operation of the printhead.

In some embodiments, the cleaning mechanism can be directed at debrisgenerating locations, such as at a moving portion of a filament movingmechanism, for example, at the interface between the gear and thefilament.

In some embodiments, the cleaning mechanism can include a blower or apressurized gas conduit for generating a gas flow, for example, at thegear, e.g., at the sharp tips of the gear, or at the gear/filamentinterface, e.g., at the places that debris is most likely generated. Insome embodiments, the cleaning mechanism can include a vacuum pump or avacuum hose, e.g., an area having low air pressure, for generating asuction, for example, at the gear or at the gear/filament interface. Insome embodiments, the cleaning mechanism can include a gas conduit and avacuum hose for both gas flowing and vacuum sucking of debris.

In some embodiments, the removal of debris can be configured to preventthe debris from falling into the heated extrusion chamber, such ascollecting the debris by the vacuum hose. For example, a vacuum hoseconnected to a vacuum pump can be used to collect debris, and disposedat an area away from the built object or the built platform. A gas flowcan be provided to assist in the dislodging of the debris. The vacuumhose can be configured to capture the flying debris, generated from thegas flow.

The debris removal can be configured to blow the debris to an area awayfrom the printhead or from the built object or from the built platform.For example, the debris removal process can be performed after theprinthead moves to a cleaning area, e.g., an area away from the builtobject, so that falling debris does not damage or contaminate the builtobject or the built platform.

FIGS. 25A-25B illustrate printheads having a cleaning mechanismaccording to some embodiments. FIG. 25A shows a side view of a printhead2500, showing cross section of gears 2520 engaging with filament 2530.FIG. 25B shows another side view of a printhead 2500, showing the sidesection of gears 2520 which is coupled to a driving motor 2525. Acleaning mechanism including a gas flowing conduit 2560 can be coupledto the printhead 2500. The gas flowing conduit can be directed at aninterface of the gear 2520 with the filament 2530, e.g., at the area2550 most likely to form debris from the friction between the gear 2520and the filament 2530. The gas flow from the cleaning mechanism 2560 canremove debris that is generated and attached to the sharp tips of thegear 2520. The gas flow can be directed away from the extrusion chamber2510, for example, to prevent debris from contaminating the extrusionchamber.

FIGS. 26A-26C illustrate integrated printheads having cleaningmechanisms according to some embodiments. In FIG. 26A, a cleaningmechanism 2660 can include a blower, which can be coupled to a printhead2600 for supplying a gas flow 2661 at an interface of gear 2620 withfilament 2630. Alternatively, the cleaning mechanism 2660 can include avacuum pump, which can be coupled to a printhead 2600 for sucking 2662debris at an interface of gear 2620 with filament 2630.

In FIG. 26B, a cleaning mechanism 2665 can include a gas flow conduit ora vacuum hose. A blower or a vacuum pump can be stationary coupled tothe printer system, such as at or near the platform. A flexible conduitcan connect the stationary blower or vacuum pump with the movingprinthead, to form a cleaning mechanism 2665 having gas flow conduit orvacuum hose conduit.

In some embodiments, both gas flow and vacuum suction can be integratedto the printhead. The gas flow can dislodge the debris, and the vacuumsuction can remove the dislodged debris. In FIG. 26C, a cleaningmechanism can include a gas flow conduit 2666 providing a gas flow 2667toward the moving portion of the filament moving mechanism. The cleaningmechanism can further include a vacuum hose conduit 2668 providing avacuum suction 2669 at the moving portion of the filament movingmechanism. Other configurations can also be used, such as a blowerinstead of a gas flow conduit, and/or a vacuum pump instead of a vacuumhose.

In some embodiments, the printhead can be configured to expose a movingportion of the filament moving mechanism. The exposure can allow anoperator to perform debris cleaning, for example, during a printingoperation or when the printhead rests at a resting location betweenprinting portions. The exposure can allow a separate cleaning mechanism,which is stationed at a cleaning location to perform the cleaningprocess. For example, between printing portions, e.g., a first printhead can print a portion of the object, and then moves to the cleaninglocation to be cleaned while a second printhead continues to print asecond portion of the object. The separate cleaning mechanism canlighten the load of the printhead, since the cleaning mechanism is notcoupled to the printhead.

FIGS. 27A-27B illustrate printheads having exposure sections accordingto some embodiments. in FIG. 27A, a portion 2760 is cut from theprinthead body 2700, exposing a cross section portion of gear 2720 atlocation 2750 where debris is likely to be generated and likely to needcleaning. In FIG. 27B, a portion 2765 is cut from the printhead body2705, exposing a side section of gear 2725 at location 2755 where debrisis likely to be generated and likely to need cleaning. An operator canclean the printhead, e.g., removing any debris at the moving portions ofthe printhead by flowing the debris away or by vacuuming the debris.Alternatively, the printhead can move to a cleaning station at which ablower or a vacuum pump can perform the cleaning.

In the description, a contact between moving gears and filament isdescribed as a debris generating mechanism, which needs to beoccasionally cleaned for optimum performance. However, the invention isnot so limited, and other debris generating mechanisms in a printheadcan also be considered, such as at the inlet of the extrusion chamberwhere the filament is inserted. In general, the present inventiondiscloses a cleaning mechanism for a printhead, which is operable forremoving debris that is generated during the operation of the printhead.

FIGS. 28A-28B illustrate a cleaning operation according to someembodiments. In FIG. 28A, a printhead 2800 can be used to print layers2870 on a heated platform 2830, which is heated by an embedded heater2835. A filament 2890 can be pulled into a heated extrusion chamber 2810by a filament moving mechanism 2820. The filament moving mechanism caninclude gear with teeth for engaging with the filament, so that therotation of the gear can correlate with the linear movement of thefilament. The extrusion chamber 2810 can be heated by a heater 2815,melting the filament 2890. The melted material can be extruded out ofthe printhead to become output material 2840 before deposited as layer2860 on the platform 2830.

The printhead 2800 can include exposure portion 2865, which shows thedebris generation area 2850. During operation, e.g., when the filamentis pulled by the filament moving mechanism 2820, some debris can begenerated, for example, by the sharp tips of the gears in the filamentmoving mechanism.

In FIG. 28B, the printhead 2800 moves to a cleaning location, e.g., alocation that is configured with a cleaning mechanism or a location thatis away from the built object 2860 or the built platform 2830. At thecleaning location, the printhead can be cleaned by a debris cleaningmechanism 2880, such as a gas flow to blow away the generated debris ora vacuum suction to vacuum the generated debris. The printhead can becleaned manually at the cleaning location by an operator, e.g., anoperator can vacuum the debris, blow the debris, or blow and vacuum thedebris. The printhead can be automatically cleaned at the cleaninglocation, e.g., a cleaning mechanism including a blower, a vacuum port,or both gas flow and vacuum suction can operate at the cleaning locationto clean the printhead at the exposed portion.

In some embodiments, the present invention discloses a printhead havingan integrated cleaning mechanism. The cleaning mechanism can include agas flow (e.g., from a blower or a gas conduit coupled to a blower)and/or a vacuum suction (e.g., from a vacuum pump or a vacuum hosecoupled to a vacuum pump), which is directed at a debris generatedportion of the printhead, such as at a filament moving mechanism, forexample, a rotating gear coupled to a filament for moving the filamenttoward an extrusion chamber.

FIGS. 29A-29B illustrate flow charts for printer systems having anintegrated cleaning system according to some embodiments. In FIG. 29A, aprinter system can include an integrated printhead, which has an activecleaning mechanism directed to a debris generating portion of theintegrated printhead. The active cleaning mechanism can include a gasflow or a vacuum portion. Operation 2900 assembles a filament movingmechanism in a 3D printhead. Operation 2910 forms a gas flow or a vacuumsuction at an interface portion of the filament moving mechanism with afilament.

In FIG. 29B, a printer system can include an integrated printhead, whichhas a passive cleaning mechanism directed to a debris generating portionof the integrated printhead. The passive cleaning mechanism can includean exposure of the debris generating portion, which can allow manualcleaning or automatic cleaning.

Operation 2930 assembles a filament moving mechanism in a 3D printhead.Operation 2940 exposes an interface portion of the filament movingmechanism with a filament.

FIGS. 30A-30B illustrate flow charts for operating printer systemshaving an integrated cleaning mechanism according to some embodiments.In FIG. 30A, a printhead can be cleaned during or after printing.Operation 3000 provides a 3D printer system having a filament movingmechanism. Operation 3010 cleans the filament moving mechanism during orafter printing.

In FIG. 30B, an operator can manually clean the printhead during orafter printing. Operation 3050 provides a 3D printhead having a filamentmoving mechanism. Operation 3060 manually cleans the filament movingmechanism to remove debris at the filament moving mechanism during orafter printing

FIGS. 31A-31B illustrate flow charts for operating printer systemshaving an integrated cleaning mechanism according to some embodiments.In FIG. 31A, a gas flow or vacuum suction can be used to clean theprinthead. Operation 3100 provides a 3D printer system having a filamentmoving mechanism. Operation 3110 continuously, intermittently, orperiodically supplies a gas flow or a vacuum suction to an interfaceportion of the filament moving mechanism with a filament. Operation 3120prints, by the 3D printer system, a material on a platform.

In FIG. 31B, the printhead can move to a station where a gas flow or avacuum suction can be applied toward the printhead for cleaning theprinthead. Operation 3150 provides a 3D printhead having a filamentmoving mechanism. Operation 3160 prints, by the 3D printhead, a materialon a platform. Operation 3170 moves the 3D printhead to a station forsupplying a gas flow or a vacuum suction to an interface portion of thefilament moving mechanism with a filament.

In some embodiments, the present invention discloses printheadassemblies, and methods to form and use the printhead assemblies, thatinclude an agitation mechanism, such as a piezo element, that isconfigured to vibrate the printing material. The agitation mechanism canbe operable to vibrate the printing material in the printhead, forexample, before the printing material is printed on the platform. Thevibration of the printing material can reduce adhesion of the materialto the nozzle of the printhead, resulting in reducing potential blockageof the nozzle, for example, by unclogging the nozzle opening due tostuck materials. The vibration can reduce the surface tension of thematerial, which can provide a smoother deposited line of material on theplatform. The smoother deposited lines can improve the surfacecharacteristics of the printed objects, such as forming smoother surfaceand improving bonding between adjacent deposited lines.

The agitation mechanism can be coupled to the printhead, e.g., to theheated chamber or the nozzle that delivers materials to the platform.The agitation mechanism can be coupled to the printhead through a waveguide, for example, a component that is operable to guide the vibrationgenerated by the agitation mechanism to the printhead. The agitationmechanism can be separated from the printhead by a thermal isolationcomponent, for example, to prevent thermal damage to the agitationmechanism by the heated printhead.

In some embodiments, a printhead assembly can include a deliveryassembly that is configured to accept a printing material and to deliverthe printing material to a printhead, e.g., a nozzle for delivering theprinting material to a platform. An agitation mechanism can be coupledto the printhead, for example, to agitate or to vibrate the printingmaterial in the printhead.

In some embodiments, the agitation mechanism can include a piezoelement, such as a piezoelectric transducer, e.g., a type ofelectroacoustic transducer device used to convert electrical signalsinto mechanical or acoustical signal. The piezo element can include apiezo material such as piezoelectric ceramics (such as PZT (leadzirconate titanate) ceramics) or single crystal materials.

In some embodiments, a printhead assembly can include a deliveryassembly that is configured to accept a printing material and to deliverthe printing material to a printhead, e.g., a nozzle for delivering theprinting material to a platform. The printhead can be heated, forexample, by a heater. A thermal isolation component can be used toseparate the delivery assembly from the heated printhead.

An agitation mechanism can be coupled to the printhead, for example,through a coupling element. The coupling element can be a wave guide,which is operable to direct the vibration generated from the agitationmechanism to the printhead. The coupling element can be a thermalisolation element, which is operable to isolate the agitation mechanismfrom the heated printhead. The coupling element can include a wave guideand a thermal isolation element. Alternatively, the agitation mechanismcan couple directly to the printhead.

FIGS. 32A-32F illustrate various configurations of printhead assembliesaccording to some embodiments. Mechanical and electrical interfaces canbe included so that the printheads can be exchangeably installed in aprinthead module. FIG. 32A shows a printhead assembly 3200, whichincludes a delivery assembly 3210 providing a printing material 3211 toa printhead 3230. The printhead 3230 can be heated by a heater 3240. Inaddition, an agitation mechanism 3270 can be coupled directly to theprinthead 3230. The agitation mechanism 3270 can include a piezoelement, such as a piezoelectric material, which can accept anelectrical signal from a power source and then convert to mechanicalenergy, vibrating the piezo element. The piezo element can vibrate theprinthead 3230, resulting in agitating the printing material in theprinthead. The vibration of the printing material can assist inseparating the printing material from the printhead nozzle, in reducingthe surface tension of the printing material, leading to smootherdeposited lines and printed object surfaces.

FIG. 32B shows a printhead assembly 3201, in which an agitation assembly3271 is coupled to the printhead through a coupling element 3281, suchas a wave guide, a thermal isolation element, or a wave guide doublingas a thermal isolation element, or a wave guide connected to a thermalisolation element.

FIG. 32C shows a printhead assembly 3202, in which an agitation assembly3272 is coupled to the printhead through a coupling element 3282, suchas a wave guide, a thermal isolation element, or any combinationthereof. A support element 3222 can be included to support the deliveryassembly 3210 against the printhead 3230. For example, support element3222 can include multiple cylinders or rods that are disposedsurrounding the printing material path from the delivery assembly to theprinthead. In some embodiments, the agitation mechanism 3272 can becoupled to the support element, such as forming a portion of the supportelement. The support element 3222 can have a shell configurationsurrounding the printing material path.

FIG. 32D shows a printhead assembly 3203, in which an agitation assembly3273 is coupled to the printhead between a support element 3229. Thevibration generated from the agitation element 3273 can pass through aportion of the support element 3229, e.g., the support element can actas a wave guide for the mechanical or acoustic vibration to travel tothe printhead. Other support elements can also be included, such assupport element 3223. Alternatively, the support element 3223/3229 canform a shell surrounding the printing material path, with the agitationmechanism 3273 coupled to a portion of the shell 3223/3229.

FIG. 32E shows a printhead assembly 3204, in which a thermal isolationor support element 3224 is used between the delivery assembly 3210 andthe printhead 3230. The element 3224 can be large, covering the deliveryassembly and the printhead areas. An agitation mechanism 3274 can becoupled to the element 3224, and can transfer the vibration energy tothe printhead through the element 3224. An optional vibration isolationelement 3284 can be used to limit or reduce the vibration energy fromreaching the delivery assembly 3210.

FIG. 32F shows a printhead assembly 3205, in which a thermal isolationor support element 3225 is used between the delivery assembly 310 andthe printhead 330. The element 3225 can be small, covering only aportion of the delivery assembly and the printhead areas. An agitationmechanism 3275 can be coupled to the element 3285, and can transfer thevibration energy to the printhead through the element 3225.

In some embodiments, the present invention discloses methods to form 3Dprinter, e.g., printhead assemblies, having agitation (or vibration)mechanism (or assembly). The agitation mechanism can include a piezoelement, e.g., an element having materials exhibiting piezo electriceffect. Other agitation elements can be used, such as motor havingoffset center. The agitation mechanism can have megasonic frequencies(e.g., above 2 MHz) or ultrasonic frequencies (e.g., between 20 kHz and2 MHz). Other frequency ranges can also be used, such as acousticfrequencies (e.g., between 20 Hz and 20 kHz).

The agitation mechanism can be coupled directly to the printhead, e.g.,connecting to a surface of the printhead, to transmit vibration energyto the printhead. The agitation mechanism can be coupled to theprinthead through a coupling element, e.g., separating from a surface ofthe printhead, to reduce or prevent heating the agitation mechanism. Thecoupling element can be used for guiding vibration energy to selectedareas of the printhead, for example, to the nozzle of the printhead.Optional vibration damping elements can be provided to isolate theagitation mechanism from other parts of the printhead assembly, forexample, preventing vibrating the delivery assembly.

In some embodiments, a controller can be provided to control thecharacteristics of the agitation mechanism, such as controlling thevibration amplitudes, vibration frequencies, and/or duration of thevibration. For example, the agitation mechanism can be continuous, e.g.,during the printing, or can be intermittent, vibrating only whennecessary.

FIGS. 33A-33B illustrate flow charts for forming a 3D printhead assemblyaccording to some embodiments. In FIG. 33A, operation 3300 couples anagitation assembly to a 3D printhead. The agitation assembly is operableto agitate the printhead or a printing material in the printhead. Acontroller can also be coupled to the agitation mechanism.

In FIG. 33B, a printhead assembly can be formed, including a printheadfor printing a printing material on a platform, a delivery assembly fordeliver the printing material to the printhead, together with anagitation assembly for vibrating the printhead or a printing material inthe printhead. Optional controllers can also be included.

Operation 3320 forms a delivery assembly for a printhead assembly. Thedelivery assembly can include a motor to drive a filament, or a motor todrive a piston to push a paste-like material to a printhead. Otherdelivery assembly can be included, such as a powder delivery system tobe used with powder printing materials.

Operation 3330 forms a printhead coupled to the delivery assembly, e.g.,the printhead is configured to accept a printing material supplied bythe delivery assembly. The printhead can include a nozzle for extrudingmolten materials, e.g., on a platform or on a previously extruded layeror line, to form a printed object. The nozzle can be a straight nozzle,e.g., perpendicular to the platform, to allow printing vertical surface,such as a wall perpendicular to a horizontal platform. The nozzle can bea tilted nozzle, e.g., forming an angle with the platform, to allowprinting non-vertical surface.

Operation 3340 forms an agitation assembly coupled to the printhead. Theagitation assembly is operable to agitate the printhead or the printingmaterial in the printhead. The agitation assembly can be coupleddirectly to the printhead, or can be separated from the printhead by acoupling element.

In some embodiments, the printhead can be heated, e.g., a heater can beprovided to heat the printhead to a temperature sufficient to soften ormelt the printing material. If the agitation assembly is heat sensitive,such as the case of piezo materials, a thermal isolation element can beprovided between the agitation element and the heated surface of theprinthead. The thermal isolation element can be used as a vibration waveguide.

In some embodiments, the present invention discloses methods to print 3Dstructures using agitation (or vibration) energy. The vibration energycan be supplied continuously or intermittently to the printhead or tothe printing material in the printhead. The vibration energy can reducesurface tension of the molten printing material, smoothing the surfaceof the printed object, together with potentially improve the adhesion ofthe new material with the existing material in the printed object. Theparameters of the vibration energy, e.g., frequency, amplitude, on-off,etc., can be adjusted to achieve a desired objective.

FIGS. 34A-34B illustrate flow charts for operating 3D printer assembliesaccording to some embodiments. In FIG. 34A, operation 3400 agitates aprinting material in a printhead for printing a 3D structure. Theagitation can be continuous, e.g., during the printing process. Theagitation can be intermittent or controllable, e.g., the printingmaterial is agitated only when needed, for example, when a smoothprinted surface is desired.

In FIG. 34B, operation 3420 supplies a material to a printhead. Forexample, a filament or a stream of paste-like material can be deliveredto a printhead from a delivery assembly. The printhead can be heated,for example, by a heater disposed in or near the printhead. A thermalisolation element can be disposed between the heated printhead and thedelivery assembly, for example, to prevent damage to the deliveryassembly by the heater. Operation 3430 agitates the material in theprinthead. Alternatively, operation 3430 can turn on an agitationassembly. Thus the agitation can be achieved by turning on the agitationassembly, such as a piezo element. The amplitude and frequency of theagitation can also be controlled to achieve a desired objective, such asa smooth printed surface, a better adhesion of the printed layer, or areduced clogging of the nozzle in the printhead. The agitation assemblycan be coupled to the printhead through a coupling element, such as athermal isolation element or a wave guide element. Operation 3440 printsthe agitated material on a platform.

In some embodiments, the present invention discloses 3D printer systemsand methods that can in-situ process the printed material. The systemscan include a radiation source coupled to a print head. In a linear xyzprinter system, the print head can move in a vertical z direction, e.g.,up and down from the support table. The support table can move inhorizontal x and y directions. Thus multiple xy plane layers can beformed on each other in the z direction to form the 3D printed object.In some embodiments, the printed material can be processed by theradiation source, for example, when the material leaves the printhead orwhen the material is deposited on the substrate. In some embodiments,the substrate can be processed by the radiation source, for example, toheat up the substrate at the printing location of the printhead.

In some embodiments, the printhead, such as a displacement piston typedelivery, can be integrated with a radiation source, such as a lightsource, which can be mounted near the tip of the nozzle of theprinthead. The light source can deliver light having wavelengths between300 and 900 nm, for example, between 400 and 600 nm.

In some embodiments, the radiation source can include an infrared (IR)light source, which can be configured to heat up the surface of thesubstrate, for example, to promote adhesion between the new printedfilament and the substrate mass. The substrate mass can be a previouslyprinted material. The substrate mass can be an existing object, operableas a platform for printing new materials. The IR source configured toheat the substrate at printing location can make practical to add aprint object to the surface of an existing block of plastic.

In some embodiments, the IR heat source can be configured to cure theprinted material, e.g., changing the property of the printed material,such as hardening a soft material once the material has left theprinthead nozzle. The hardening process can allow for printing tallerbuilt objects, e.g., without temporary support structures.

In some embodiments, the radiation source can include an ultraviolet(UV) light source, which can be configured to change a property of theprinted material, for example, to cross link a polymer material or tocause a material that is being dispensed to cure rapidly. For example, asoft material can be printed and then cross linked once the material hasleft the printhead nozzle to assist in solidifying the material.

In some embodiments, a print head can include an extrusion head having aheater for heating the extruded material that is supplied to theextrusion head. A radiation source can be coupled to the extrusion head,providing radiation on the substrate, such as the existing material onthe support table. A heater can be couple to the support table 230 forheating the table surface.

FIGS. 35A-35D illustrate different radiation sources according to someembodiments. A print head 3510 can have a radiation source 3541providing a diffuse radiation beam 3551 to the support platform (FIG.35A). For example, a point source can be used to irradiate a large areaof the substrate. The print head can have a radiation source 3542providing a parallel beam 3552 to the support platform (FIG. 35B). Forexample, a point source with a parabola mirror can be used to formparallel beam of radiation. The print head can have a radiation source3543 providing a focused beam 3553 to the support platform (FIG. 35C).For example, a point source with a focusing lens can be used to focusthe radiation to a small area on the substrate. The print head can havea radiation source 3544 providing a small parallel beam 3554 to thesupport platform (FIG. 35D). For example, a laser source can be used toirradiating a small area on the substrate.

In some embodiments, the present invention discloses a printhead havinga radiation source coupled to the printhead, e.g., the radiation sourceis operable to move with the printhead, so that the radiation source canirradiate an area on the substrate that the printhead is to be printedon, or the radiation source can irradiate on the material leaving theprinthead. The irradiation source can be a single source, or multiplesources surrounding the printhead. In some embodiments, a mechanism canbe provided to adjust the location, or the focus of the radiation beam.

FIGS. 36A-36B illustrate different radiation sources according to someembodiments. In FIG. 36A, multiple radiation sources 3640A/3640B can becoupled to printhead 3610. The multiple radiation sources 3640A/3640Bcan be configured to irradiate a same area on the substrate, such asfocused beam, parallel beam, or diffuse beam. The radiation sources caninclude visible light source, IR light source, UV light source, or laserlight source.

In FIG. 36B, a ring of radiation source 3641 can be coupled to theprinthead 3610. The radiation ring 3641 can be configured to provideirradiation at the built zone, e.g., the area on the substrate that theprinthead is ready to print a material, or to the material that justleaves the printhead. In some embodiments, the radiation ring caninclude multiple discrete radiation sources, such as light emittingdiodes (LEDs) arranged in a configuration surrounded the printhead. Themultiple discrete radiation sources can be configured to provide a lightbeam to an area on the substrate. In some embodiments, the radiationring can include one or more continuous radiation sources, such as aring of fluorescence tube arranged in a configuration surrounded theprinthead. The continuous radiation sources can be configured to providea light beam to an area on the substrate, for example, through mirrorsand lenses.

In some embodiments, the present invention discloses a print head havinga radiation source that is operable to heat a local area of thesubstrate. For example, the radiation source can irradiate, e.g.,heating, an area between 2× and 100×, such as between 2× and 50 C, or 2×and 10× the area dimension of the printed filament printed from theprinthead. The radiation source can irradiate an area greater than 100microns and less than a few millimeters, such as less than 10 mm, orless than 5 mm, or less than 2 mm, or less than 1 mm in one lateraldimension.

The radiation source can also be configured to heat only a surfaceportion of the substrate. For example, the radiation source can beoperable to heat between 10 and 40% of a previously printed layer. Theradiation source can be operable to heat a depth greater than 100microns and less than a few millimeters of the substrate, such as lessthan 10 mm, or less than 5 mm, or less than 2 mm, or less than 1 mm insubstrate thickness.

FIGS. 37A-37B illustrate a printing process of printhead having aradiation source according to some embodiments. In FIG. 37A, a radiationsource can be configured to heat the surface of the object, for example,to improve the adhesion with the newly printed material. The integrationof the radiation source can accelerate print times, for example, bystarting with an existing object, such as a block or plate of plasticsubstrate, which is mass produced. The printhead then can print on theexisting object, thus the print time can be significantly reduced, forexample, by the time it takes to print the mass-produced existingobject.

In some embodiments, the radiation source can be a radiant heat source,which is located on the moving printhead in such a way as to focus theheat in the area that is about to be fused. The heated substrate canincrease the penetration of the bond between the substrate and thefreshly deposited material.

The local and surface heating of the substrate can improve the adhesionbetween the deposit material with the substrate. For example, withoutheating the substrate, dispensing hot material, e.g., plastic, on top ofa block of cold plastic, the hot plastic can be cooled by the mass ofthe cold block, reducing adhesion. In some embodiments, locally andsurfacely heating the substrate surface can improve bonding strength,for example, up to 100×, and can make it practical to print customfeatures on otherwise standard size substrates or objects.

The heat source can be an IR heater. Other heaters can also be used,such as a laser. The head source can be an IR focusable heat sourceattached to print head in such a way as to allow local zone heating inthe area that is about to have fresh material deposited.

A radiation source, such as an IR light source 3740, can be coupled to aprinthead 3710 to provide IR radiation 3745 on a surface area 3780 of anobject 3760. The object 3760 can be placed on a platform 3730, which canbe heated be a heater 3735. The object 3760 can be an object brought infrom outside, or can be an object that the printhead has just printed.

The radiation source 3740 can be operable to heat up a local and surfacearea 3765 of the object 3760. The heating of the local surface area 565can improve an adhesion of the newly printed material 3770 with theexisting object 3760. For example, the local surface heating process canallow printing of additional structures on an existing object withadequate adhesion. The radiation source can be configured to heat thelocal surface area to a temperature that can provide good adhesion witha newly printed material, such as close to the melting temperature ofthe object material (or even higher than the melting temperature), oraround (e.g., slightly lower or higher) a softening temperature of theobject material. Since the heating is localized, e.g., in both lateraland depth dimensions, the high temperature heating does not affect thestructure integrity of the object.

In FIG. 37B, a radiation source can be configured to process the printedmaterial, for example, to solidify or to strengthen the printedmaterial. The integration of the radiation source can improve structureintegrity of printed soft material such as soft polymers, for example,by rapidly curing the material as the material is being deposited. Theintegration of a radiation source configured to immediately cure theprinted material can allow printing tall 3D structures, such asoverhangs or tilted beams. Without the immediately cured radiationsource, long cure times (e.g., >10 seconds) can be required, which canresult in the lower uncured layers not able to support the new layersbeing dispensed.

In some embodiments, the present invention discloses new materials,e.g., soft light activated materials such as UV curable silicone, whichcan be printed and simultaneously accelerate the fixing process.

A radiation source, such as an IR or UV light source 3741, can becoupled to a printhead 3710 to provide IR or UV radiation 3746 on aprinted material leaving the printhead 3710 and disposed on a substrate.

The radiation source 3741 can be operable to cure or cross link theprinted material 3771. The curing or cross linking of the printedmaterial 3771 can improve a structural integrity of the newly printedmaterial 3771, allowing taller structures or other structures withouttemporary supports. For example, the material leaving the printhead, orthe material disposed on the substrate surface can be irradiated tostrengthen a hardness of the material. The radiation source can beconfigured to heat the material, or to stimulate a chemical reaction,e.g., cross linking a polymer material, to improve a property of theprinted material.

In some embodiments, the radiation source is configured to be movable,such as moving around the print head to change the location of the areato be irradiated. A controller can be used to control the intensityand/or frequency of the radiation, allowing optimizations of the surfacetreatment or the treatment of the printed material.

In some embodiments, the present invention discloses an integratedprinthead having an attached radiation source, such as a light source.The radiation source can be used to create or relieve stress in theprinted material.

FIGS. 38A-38C illustrate flow charts for forming print heads having aradiation source according to some embodiments. In FIG. 38A, operation3800 couples a radiation source to a 3D printhead. The radiation sourcecan be configured to supply radiation to a local area on a substrate.

In FIG. 38B, operation 3820 couples a radiation source to a 3Dprinthead. The radiation source can include an IR light or a laser. Theradiation source can be configured to heat a substrate locally and onthe surface.

In FIG. 38C, operation 3840 couples a radiation source to a 3Dprinthead, wherein the radiation source comprises an UV light. Theradiation source is configured to vary a structure of a material whichleaves the 3D printhead to be disposed on a substrate surface.

FIGS. 39A-39B illustrate flow charts for forming print heads having aradiation source according to some embodiments. In FIG. 39A, operation3900 couples a radiation source to a 3D printhead. The radiation sourcecan be configured to supply radiation to a surface of the substrate. Theradiation source can surround a nozzle of the 3D printhead. Theradiation can be operable to heat a local area of the substrate. Theradiation can be operable to heat a top surface portion of thesubstrate. The radiation can be configured to provide a focused,diffused or parallel beam to a surface area of the substrate where the3D printhead supplies a printing material. The radiation source caninclude a laser. The radiation source can include an IR lamp.

In FIG. 39B, operation 3930 couples a radiation source to a 3Dprinthead. The radiation source can be configured to supply radiation toa surface of the substrate or to a material leaving a nozzle of the 3Dprinthead or to a material deposited on the substrate from the 3Dprinthead. The radiation source can surround a nozzle of the 3Dprinthead. The radiation can be operable to heat a local area of thesubstrate. The radiation can be operable to cross link the materialleaving or deposited on the substrate from the nozzle of the 3Dprinthead. The radiation source can include a UV lamp.

FIGS. 40A-40C illustrate flow charts for operating print heads having aradiation source according to some embodiments. In FIG. 40A, operation4000 irradiates a surface of a substrate. The radiation can beconfigured to be confined to a local area. The radiation can beconfigured to heat a top portion of the surface. Operation 4010 3Dprints a material on the irradiated surface. The irradiated surface canbe configured to enhance an adhesion of the material.

In FIG. 40B, operation 4040 prints a first layer of a first material ona substrate. Operation 4050 locally and surfacely irradiates the firstlayer while or before or after 3D printing a second material on thefirst layer. The first and second materials have different meltingtemperature.

In FIG. 40C, operation 4070 provides an object on a substrate. Operation4080 locally and surfacely irradiates a surface of the object while orbefore or after 3D printing a material on the object. The material isadhered to the heated surface of the object.

FIGS. 41A-41B illustrate flow charts for operating print heads having aradiation source according to some embodiments. In FIG. 41A, operation4100 irradiates a printed material with a UV light. The radiation can beconfigured to solidify or cross link the printed material.

In FIG. 41B, operation 4120 3D prints a material on substrate. Operation4130 irradiates the material with a UV light. The radiation can beconfigured to solidify or cross link the printed material. The radiationcan be provided to the material after being disposed on the substrate orto the material at the nozzle output.

In some embodiments, the present invention discloses modular printheadsfor a printer system. The modular printheads can have differentconfigurations, operations, functionalities, and characteristics. Forexample, different printheads can be configured with different colorprinting materials.

FIGS. 42A-42D illustrate different printheads according to someembodiments. FIG. 42A shows a printhead together with a worm gear 4220for accepting a filament 4210. FIG. 42B shows a printhead together witha piston 4221 for delivering a paste-like material 4211. FIG. 42C showsa printhead together with a worm gear 4222 for accepting a differentfilament 4212. FIG. 42D shows a multiple nozzle printhead together witha worm gear 4223 for accepting a filament 4213. The multiple nozzleprinthead can print multiple lines at a same time from the multiplenozzle configurations. The multiple nozzle configurations can providefast printing of layers, either by filling printing or by hollowprinting.

In some embodiments, the printhead can include a mixer. For example,multiple filaments can be inputted to the printhead with one outlet,mixing the filament inputs. Filaments with different properties, such ascolor, can be mixed together to form a new material. For example, oneinput can be a base plastic filament, and one input can be a dieinjection control for changing the color of the output material. The dieinjection control can be another plastic filament with color designed tobe combined with the base plastic filament. The die injection controlcan include liquid, paste or solid die, designed to be mixed with thebase plastic filament to achieve a desired color.

Other properties can be mixed. For example, one input can be a baseplastic filament, and one input can be a particle injection control foradding particles to the output material.

FIGS. 43A-43B illustrate a printhead having multiple inputs and onemixed output according to some embodiments. In FIG. 43A, a printhead4310 can include a heater 4315 for heating the material delivered to theprinthead. Printing materials, such as plastic filaments 4320/4325, canbe driven into the printhead by rotating gear mechanisms. At the heatedprinthead 4310, the plastic filaments 4320/4325 can be melted to becomemolten plastics 4330/4335. The molten plastics 4330/4335 can be mixedand then driven out of the printhead, for example, through a nozzle atthe end of the printhead. The mixed material 4340, out of the printhead,can be deposited on a heated platform.

As shown, the multiple inputs are solid filaments 4320/4325. Otherconfigurations can be used, such as one solid filament and one liquid,paste, powder, or particle input. In addition, more than two inputs canbe used.

FIG. 43B shows various cross sections BB′ of the printed material 4340.The material 4340 can be a well mixed 4341 of the multiple inputs. Thematerial 4340 can include a center mixed portion 4342 between minimummixed inputs 4311 and 4316. Other mixed configurations can be used, suchas multiple mixed portions. For example, a four material print head thathas 4 independent feed motors, and one output can be used for mixingmaterials and getting on-the-fly color control. A dye injection systemcan be used as the inputs for the printhead for color control.

In some embodiments, the mixing chamber of the printhead can be rotated.The nozzle of the printhead can be disposed on a rotary bearing and canspin as the material is deposited on the platform. The spinning chambercan improve the mixing of the multiple input materials. For example, thespinning chamber can create spiral thread of fully mixed, partiallymixed, or non-mixed materials. Further, the spinning chamber can allowmechanical integration of non-mixable materials, such as a fiber threadinside a fused material. The spinning chamber can also allowco-extrusion, generating multiple stripes of different materials thatwould not interact chemically with each other. This can create materialsthat can stretch and contract. For example, piezo materials, such aspvdf, can be used to create micro sensors that are embedded in the builtplastic part.

FIGS. 44A-44C illustrate a printhead having a spinning mixer accordingto some embodiments. In FIG. 44A, a printhead 4410 can include a heater4415 for heating the material delivered to the printhead. Printingmaterials, such as plastic filaments 4420/4425, can be driven into theprinthead by rotating gear mechanisms. At the heated printhead 4410, theplastic filaments 4420/4425 can be melted to become molten plastics4430/4435. The molten plastics 4430/4435 can be mixed in a rotatingmixer 4450, which can be rotated 4455. The mixed material is then drivenout of the printhead, for example, through a nozzle at the end of theprinthead. The mixed material 4440, out of the printhead, can bedeposited on a heated platform.

As shown, the multiple inputs are solid filaments 4420/4425. Otherconfigurations can be used, such as one solid filament and one liquid,paste, powder, or particle input. Other types of filaments can be used,such as fiber filaments. In addition, more than two inputs can be used.

FIG. 44B shows an output material 4440 that can be twisted from therotating mixer 4450. The input feeding rates and the spinning rate canbe configured to form twisted output. In some embodiments, the outputmaterial can be a smooth columnar filament, e.g., without the twistedconfiguration.

FIG. 44C shows various cross sections CC′ of the printed material 4440.The material 4440 can include a well mixed 4441 of the multiple inputs.The material 4440 can include a center mixed portion 4442 betweenminimum mixed inputs 4411 and 4416. The material 4440 can includeunmixed inputs 4412 and 4417. Other mixed configurations can be used,such as multiple mixed portions.

In some embodiments, the present invention discloses a printhead havinga rotatable mixing portion for mixing multiple inputs. The rotatingmixer can improve the mixing of the multiple inputs. The rotating mixercan provide twisted or braided output material, with different degreesof mixing between the multiple inputs. For example, each input can forma strand of the twisted output, with minimum or no mixing between thestrands. Each input can also form a strand of the twisted output, withan outer portion of the strand mixed with a neighbor strand. Therotating mixer can integrate multiple inputs that are not mixable, forexample, through twisting or braiding the multiple inputs to formmultiple strands of the output material.

FIGS. 45A-45B illustrate flow charts for printer systems having arotatable mixer according to some embodiments. In FIG. 45A, a printersystem can accept multiple inputs and rotatably mix the inputs, eitherforming a well mixed output or a twisted/braided output with individualstrands. Operation 4500 supplies multiple materials to a rotatableportion of a 3D printhead. Operation 4510 rotates the rotatable portionto mix or twist the multiple materials together. Operation 4520 prints,by the 3D printhead, the mixed or twisted materials on a platform.

In FIG. 45B, at least one input material has a different property thanthe other input materials. For example, the different property caninclude color property, allowing generating different color output, orallowing generating strands having different colors of a twisted orbraided output. The different properties can include strength, hardness,compression, or tension. Operation 4540 mixes or twists multiplematerials, wherein at least two materials of the multiple materials havea different property, wherein the different property comprises at leastone of color, strength, hardness, or melting temperature. Operation 4550prints, by the 3D printhead, the mixed or twisted materials on aplatform.

In some embodiments, the non-mixable materials can be integratedtogether, for example, by twisting, braiding, or simply putting thematerials together.

FIGS. 46A-46C illustrate a printhead having a spinning mixer accordingto some embodiments. In FIG. 46A, a printhead 4610 can include a heater4615 for heating the material delivered to the printhead. Printingmaterials, such as plastic filaments 4620/4625, can be driven into theprinthead by rotating gear mechanisms. At the heated printhead 1810, theplastic filaments 4620/4625 can be melted to become molten plastics4630/4635. The molten plastics 4630/4635 can be mixed in a rotatingmixer 4650, which can be rotated 4655. Another input 4670 can beprovided to a middle of the mixer 4650, which can stay at a center ofthe output material 4640 with the molten plastics 4630/4635 spinningaround.

The mixed material is then driven out of the printhead, for example,through a nozzle at the end of the printhead. The mixed material 4640,out of the printhead, can be deposited on a heated platform. The mixedmaterial 4640 can include a mixed material, e.g., twisted or braidedmaterials, surrounding a center material.

As shown, the multiple inputs are solid mixable filaments 4620/4625surrounding a non-mixable filament 4670 such as fiber filament. Otherconfigurations can be used, such as one solid filament and one liquid,paste, powder, or particle input. Other types of filaments can be used,such as metal or fiber filaments. In addition, more than two inputs canbe used.

FIG. 46B shows a cross section of an output material 4640 that can betwisted from the rotating mixer 4650. A center filament 4670, such as afiber filament, can be surrounded by twisted filaments to form compositeoutput 4640. In some embodiments, the output material can be a smoothcolumnar filament, e.g., without the twisted configuration.

FIG. 46C shows various cross sections CC′ of the printed material 4640.The material 4640 can include a well mixed 4641 of the multiple inputssurrounding a center non-mixable portion 4670. The material 4640 can beinclude a center mixed portion 4642 between minimum mixed inputs 4611and 4616, surrounding a center non-mixable portion. The material 4640can be include unmixed inputs 4612/4617 and 4613/4618, surrounding acenter non-mixable portion. Other mixed configurations can be used, suchas multiple mixed portions.

In some embodiments, the present invention discloses a printhead havinga rotatable mixing portion for mixing multiple inputs, with at least aninput is not mixable with at least another input. The rotating mixer canprovide twisted or braided output material, with different degrees ofmixing between the mixable inputs and with a non-mixable integratedwithin. For example, the non-mixable input can be positioned at a centerportion, with the mixable inputs forming strands of the twisted output,with mixing or no mixing between the strands.

FIGS. 47A-47B illustrate flow charts for printer systems having arotatable mixer according to some embodiments. In FIG. 47A, a printersystem can accept an input at a middle portion of a printhead and one ormore inputs at a peripheral portion of the printhead. Operation 4700supplies a first material to a middle portion of a rotatable assembly ofa 3D printhead. The first material can be a non-mixable material, suchas a fiber filament. Operation 4710 supplies one or more secondmaterials to a peripheral portion of the rotatable assembly. The secondmaterials can be mixable with each other, and non-mixable with the firstmaterial. Operation 4720 rotates the rotatable portion, wherein the oneor more second materials are mixed or twisted together around the firstmaterial. Operation 4730 prints, by the 3D printhead, the mixed ortwisted materials on a platform.

In FIG. 47B, one or more second materials can be twisted or braidedaround a first material. Operation 4750 mixes or twists multiple secondmaterials around a first material. Operation 4760 prints, by the 3Dprinthead, the mixed or twisted materials on a platform.

In some embodiments, different materials can be printed with differentprint head configurations. Solid materials can be extruded from a heatedextrusion chamber. Paste materials can be extruded from a squeezechamber. Liquid materials can be delivered by a liquid pump such as aperistaltic pump.

FIGS. 48A-48C illustrate different print heads according to someembodiments. In FIG. 48A, a solid material 4820 in the form of a wirecan be provided to a print head 4810. The print head can be heated, forexample, by a heater 4815. The melted or softened material can beextruded out of the print head to be delivered on a support surface,such as a support table or a previously printer surface.

In FIG. 48B, paste material 4830 can be provided to a print head 4812. Aplunger 4850 can be used to extrude the material out of the print head.Optional heater 4815 can be used to heat the paste material. In FIG.48C, liquid material 4842 can be provided to a print head. A peristalticliquid pump 4840 can be used to deliver the liquid material. Forexample, a rotatable mechanism 4846 can be used to squeeze deliveringtube 4844, to move the liquid from a reservoir to the nozzle 4817. Theperistaltic pump can prevent contamination of the printed material, andcan allow the use of different materials for printing without beingcontaminated by the pump.

FIG. 49 illustrates a peristaltic print head according to someembodiments. A peristaltic pump 4940 can deliver a liquid material 4942from a reservoir to a nozzle 4917. A mechanism 4950 can be configured tochange 4952 the tilted angle of the nozzle 4917, forming a print headhaving a tilted nozzle. Another mechanism 4960 can be configured torotate the nozzle 4917. For example, the peristaltic pump 4940 can berotated through a rotatable seal 4962. In some embodiments, a solidifymechanism, such as a cooler, can be coupled to the print head tosolidify the liquid material. The liquid material can be in a pasteform, and when delivered on a cold substrate, can be further solidifyinto solid form.

FIG. 50 illustrates a printing system using a peristaltic pump accordingto some embodiments. A print head 5010 can include a peristaltic pump5040 to a nozzle. An optional heater 5015 can be used to regulate thetemperature of the liquid. The temperature of the environment of theprint head can be regulated to allowing printing liquid materials. Forexample, a cooling system 5025 can be coupled to a support platform 5020to keep the delivered materials at a solid state. Further, the printhead can be placed in a controlled environment 5030, which can regulatethe temperature of the printed materials.

FIGS. 51A-51B illustrate flow charts for printing liquid materialsaccording to some embodiments. In FIG. 51A, operation 5100 pumps aliquid to a 3D print head. Operation 5110 prints the liquid on a surfaceto form a solid object. The surface and the environment of the printingprocess can be kept at a temperature to solidify the liquid material.

In FIG. 51B, operation 5130 uses a peristaltic pump to deliver a liquidto a nozzle of a print head. Operation 5140 positions the print head inan environment having a temperature below room temperature. Theenvironment can be configured to solidify the materials delivered fromthe print head. Operation 5150 prints the liquid on a surface in theenvironment, such as a cold support surface. The liquid can be partiallyfrozen when leaving the printer nozzle, and further solidify afterreaching the support surface.

In some embodiments, a liquid printhead, e.g., a printhead having aliquid pump (such as a peristaltic pump) for delivering a liquid, can beused in conjunction with a non-liquid printhead, e.g., a printhead nonconfigured to deliver a liquid, such as a solid printhead (e.g., aprinter hear configured for delivering a soften or melted solid materialthat can be solidified after leaving the printhead) or a paste printhead(e.g., a printer hear configured for delivering a paste material thatcan be solidified after leaving the printhead). Two or more printheadscan be used in a 3D printing system with at least one printhead being aliquid printhead.

In some embodiments, the liquid printhead can be used to separate thesolid layers. For example, two objects can be printed together. The twoobjects can be prevented from adhering to each other by a layer ofliquid in between, such as a layer of lubricant materials, such as anoil layer delivered by a liquid printhead configured to deliver oil. Alayer of the first object can be printed, followed by a layer of liquid,such as oil. The liquid layer can printed on a portion of the firstlayer or on the whole first layer. A layer of the second object can beprinted on the liquid layer. The process can be repeated until the twoobjects are printed.

In some embodiments, the liquid printhead can be used to improve theadhesion of two layers. For example, two layers can be printed with anaddition liquid adhesion layer in between to improve the adhesion ofthese two layers. In some embodiments, a paste printhead can beconfigured to deliver a layer of lubricant or a layer of adhesion.

FIGS. 52A-52C illustrate a printing system according to someembodiments. In FIG. 52A, two printheads 5201 and 5202 can be installedin a 3D printing system. In some embodiments, at least one of theprintheads is a liquid printhead.

In FIG. 52B, a 3D printing system 5205 can include a solid printhead5210 and a liquid printhead 5217. In the solid printhead 5210, a solidmaterial 5220 in the form of a wire can be provided to a print head5210. The print head can be heated, for example, by a heater 5215. Themelted or softened material can be extruded out of the print head to bedelivered on a support surface, such as a support table or a previouslyprinter surface. In the liquid printhead 5217, a liquid material 5242can be provided to a nozzle head. A peristaltic liquid pump 5240 can beused to deliver the liquid material. Other liquid pump can also be used.The operation of a peristaltic pump is shown, in which a rotatablemechanism 5246 can be used to squeeze delivering tube 5244, to move theliquid from a reservoir to the nozzle head.

In FIG. 52C, a 3D printing system 5207 can include a paste printhead5212 and a liquid printhead 5217. In the solid printhead 5212, pastematerial 5230 can be provided to a print head 5212. A plunger 5250 canbe used to extrude the material out of the print head. Optional heater5215 can be used to heat the paste material. In the liquid printhead5217, a liquid material 5242 can be provided to a nozzle head. Aperistaltic pump is shown, but other liquid pump can be used. Otherconfigurations for a printing system can be used, such as a solidprinthead and a paste printhead.

FIG. 53 illustrates a 3D printing system according to some embodiments.A printing system 5300 can include multiple printheads 5390, 5391, 5392,. . . , 5399. In some embodiments, at least one of the printheads is aliquid printhead, which is configured to deliver a liquid layer, such asa lubricant layer or a non-stick layer. In some embodiments, the liquidprinthead can be configured to deliver an adhesion layer, such as a gluelayer, to bond to adjacent layers. For example, multiple solid or pasteprintheads can be used with one or more liquid printheads.

In some embodiments, a paste printhead can be used in place of theliquid printhead to deliver a separation layer (such as a lubricantlayer), or an adhesion layer (such as a glue layer). In someembodiments, at least one of the printheads is a paste printhead, whichis configured to deliver a paste layer, such as a lubricant layer, anon-stick layer, or an adhesion layer. For example, multiple solid orpaste printheads can be used with one or more paste printheads.

FIG. 54 illustrates a flow chart for 3D printing according to someembodiments. In operation 5400, a 3D printing system can be provided.The 3D printing system can include a liquid printhead and a non-liquidprinthead, e.g., a paste printhead or a solid printhead. Operation 5410prints a first non-liquid layer, such as a solid layer from the solidprinthead or a paste layer from the paste printhead. The non-liquidlayer can be solidified, for example, on the support surface. The firstlayer can be a line, such as a straight line or a curve line, a dot, ora plane, such as a linear plane or a curve plane. Operation 5420 printsa liquid layer over at least a portion of the first layer. The liquidlayer can be printed on a portion of the first layer that can provide anadded characteristic, such as preventing adhesion or enhancing adhesion.Operation 5430 prints a second non-liquid layer on the liquid layer. Theliquid layer can prevent the first and second layers from being stucktogether. Alternatively, the liquid layer can enhance the adhesionbetween the first and second layers. In some embodiments, the secondlayer can be printed directly on a portion of the first layer, e.g., onthe portion of the layer that is not printed with the liquid layer.

In some embodiments, a paste printhead can be used in place of theliquid printhead to deliver a separation layer (such as a lubricantlayer), or an adhesion layer (such as a glue layer).

In some embodiments, a mist can be delivered, instead of a liquid orpaste layer. A printhead can be configured to deliver a fine mist over afirst layer before printing a second layer, to either prevent stickingor to increase adhesion.

In some embodiments, a brush of layer can be delivered, instead of aliquid or paste layer. A printhead can be configured to brush a layerover a first layer before printing a second layer, to either preventsticking or to increase adhesion.

In some embodiments, the present invention discloses a platform supporthaving a mechanical interface and an electrical interface. Theinterfaces can be configured to be mated with a platform module, e.g., aplatform support can be installed in a platform module with matedmechanical and electrical interfaces. Serial bus, such as CAN bus, canbe used for electrical communication between the platform support andthe platform module (and also the 3D printer system). The platformsupport can include information to allow automatic configuration, e.g.,the platform support can send information related to the printheadphysical characteristics and functionalities, so that a systemcontroller can control the platform support.

The modular system can thus be configured for different job requirementsby selecting the platform support suitable for the job. The selectioncan be performed manually by an operator. In the present specification,the platform support can be shown with or without the interfaces with aplatform module. However, it is understood that interfaces are implied,and thus an exchangeable platform support can have both mechanical andelectrical interfaces for mating with the platform module.

In some embodiments, the platform supports can be used independently,e.g., without the mechanical and/or electrical interfaces. A platformsupport can be used in a 3D printer system, e.g., secured to the 3Dprinter system without the removable interfaces.

In some embodiments, the present invention discloses 3D printer systemsand methods that can automatically generate a pattern on a bottomsurface of the printed material. The systems can include a platformhaving a reverse, e.g., negative, image of a pattern. When an object isformed on the platform, the pattern can be transferred, from theplatform to the bottom surface of the object.

In some embodiments, the patterned platform can be a support table of a3D printer system. For example, in a linear xyz printer system, theprint head can move in a vertical z direction, e.g., up and down fromthe support table. The support table can move in horizontal x and ydirections. Thus multiple xy plane layers can be formed on each other inthe z direction to form the 3D printed object. The bottom surface of theobject, since being disposed on the platform, will have the patternimprinted on it. The transferred pattern can be a reverse image, such asa mirror image of the pattern on the platform. Further, if the patternon the platform is a recess or depression pattern, the transferredpattern on the object will be a hump or protruded pattern. Similarly, ifthe pattern on the platform is a hump or protruded pattern, thetransferred pattern on the object will be a recess or depressionpattern.

In some embodiments, the platform can be a substrate provided togenerate a pattern on a printed surface of the object. The substrate canbe disposed in any direction, e.g., parallel to the support table orforming an angle with the support table. The substrate can be atemporary substrate, provided only during the formation of the objectsurface having the pattern. For example, the pattern substrate can havea vertical surface, allowing a pattern transfer on a vertical surface ofthe object.

The patterned platform can also improve an adhesion of the object to thesupport table during the printing process, since the pattern can assistin keeping the object in place.

In some embodiments, the thickness of the pattern can be less than thethickness of a printing layer. For example, a printing layer can be0.1-0.2 mm thick, and the thickness of the pattern, e.g., the depth of arecess pattern or the height of a protruded pattern, can be less than0.1-0.2 mm, such as 0.05-0.08 mm, or 0.05-0.15 mm. The shallowness ofthe pattern can allow a formation of watermark pattern on the object,e.g., a pattern having thin impression.

In some embodiments, the first few printed layers of the object can havehigh thickness, such as less than 1-2 mm or even less than 5 mm thick.The high thickness can allow faster printing of an object, for example,when printing a solid base for the object. The high thickness of thebase layers of the object can allow higher depth or height of thepattern, e.g., pattern having less than 5 mm, or less than 1-2 mm thick.In some embodiments, the thickness of the pattern can be higher than thethickness of a printing layer.

FIGS. 55A-55C illustrate 3D printer systems according to someembodiments. In FIG. 55A, a print head can include an extrusion head5510 having a heater 5515 for heating the extruded material 5501 that issupplied to the extrusion head 5510. The printhead can print material5520 on a platform, such as a support table 5530. A heater 5535 can becouple to the support table 5530 for heating the table surface 5550. Theplatform 5530 can have a pattern 5555, embedded on the surface 5550. Asshown, the pattern 5555 is embedded to the platform surface 5550. Otherconfigurations can be used, such as a pattern protruded from theplatform surface. FIG. 55B shows a top view of the platform 5530,looking at line AA′. Embedded pattern 5555 can be provided on thesurface of the platform 5530.

In FIG. 55C, a print head 5510 can have a tilted nozzle 5540. The tiltednozzle 5540 can form an angle 5545 with the support table 5530. Aplatform 5560 having pattern 5565 can be provided. The platform 5560 canbe placed on the support table 5530, forming a perpendicular angle withthe support table. The print head can be moved in a vertical directionto form a vertical wall 5520. For example, a first line can be formed,followed by a second line directly disposed on the first line. The linescan be directly placed on top of each other to form a vertical wall5520. The vertical wall 5520, since being disposed on the platform 5560,can have the pattern 5565, which is transferred from the platformsurface.

As shown, the platform 5560 is perpendicular to the support table andcontacts the support table. Other configurations can be used, such as aplatform forming an acute angle or an obtuse angle. Further, theplatform can be independent to the support table, e.g., having separatesupport and not coupled with the support table. As shown, a tiltednozzle 5540 is used to print a vertical wall 5520 in contact with apatterned platform 5560, but other configurations can be used, such as astraight nozzle.

FIGS. 56A-56B illustrate patterning processes on printed objectsaccording to some embodiments. In FIG. 56A, a recess pattern 5651 can beembedded on a surface 5650 of a platform 5630. The recess pattern 5651can include recesses or indentations on the surface 5650 to form anegative image of the pattern. When a first layer 5620 is printed on thepattern surface 5650, some material can fill the recesses of the recesspattern 5651, forming dimples 5661 on a top surface of the first layer5620. In some embodiments, the recess depth is less than the thicknessof the printed line 5621, so subsequent layers 5620 can smooth out thedimples. The filling of the recesses in the recess pattern 5651 canprevent the object from movement in a lateral direction, thus improve anadhesion of the printed object with the platform 5630. The filling ofthe recess pattern can transfer the pattern from the platform to theobject, forming a protruded image.

In FIG. 56B, a protruded pattern 5656 can be imposed on a surface 5655of a platform 5635. The protruded pattern 5656 can include protrusionsor humps on the surface 5655 to form a negative image of the pattern.When a first layer 5625 is printed on the pattern surface 5655, somematerial can avoid the protrusions of the protruded pattern 5656,forming protrusion 5666 on a top surface of the printed line 5625. Insome embodiments, the protrusion height is less than the thickness ofthe printed line, so subsequent layers 5626 can smooth out theirregularities. The protrusions in the protruded pattern 5656 canprevent the object from movement in a lateral direction, thus improve anadhesion of the printed object with the platform 5635. The printing onthe protruded pattern can transfer the pattern from the platform to theobject, forming a recess image.

In some embodiments, the present invention discloses a printer systemhaving a patterned platform. The patterned platform can automaticallyprovide a pattern on a surface on the printed objects. The patternedplatform can provide a watermark on the printed objects, e.g., a shallowimage. The platform can have a pattern directly applied on a surface.Alternatively, a platform can include a pattern layer on a top surface.

FIGS. 57A-57D illustrate patterned platforms according to someembodiments. In FIG. 57A, a recess pattern 5751 can be formed directlyon a surface of a platform 5730. In FIG. 57B, a protruded pattern 5756can be formed directly on a surface of a platform 5731.

In some embodiments, a pattern can be provided in a layer, which isapplied on a surface of a platform. The layer can provide a control forthe depth or height of the pattern, e.g., the pattern is limited by thethickness of the layer. FIG. 57C shows a recess pattern 5752 on a layer5750, which is deposited on a platform 5735. FIG. 57D shows a protrudedpattern 5757 on a layer 5755, which is deposited on a platform 5736.

FIGS. 58A-58E illustrate a process of forming a recess pattern on alayer on a platform according to some embodiments. In FIG. 58A, asubstrate 5830, which is configured to be a platform for a 3D printersystem, can be provided. The substrate can be a high thermal conductivematerial. For example, the substrate 5830 can be an aluminum platehaving thickness less than 10 mm, such as less than 5 mm, or about 3 mm.In FIG. 58B, a layer 5840 can be formed on the substrate 5830. The layer5840 can be a high thermal conductive material. For example, the layer5840 can be a copper layer having thickness of less than 2 mm, such asless than 0.5 mm, or less than 0.2 mm, or less than 0.1 mm, such asabout 0.08 mm. The layer 5840 can be deposited on the substrate 5830.For example, an electroplating process can be used to deposit a copperlayer on an aluminum substrate. In FIG. 58C, a pattern layer 5850 can beformed on the copper layer 5840. The pattern layer 5850 can be aphotoresist pattern layer, formed by coating a photoresist layer, andthen exposing a pattern on the photoresist layer through a mask. Theexposed photoresist layer can be removed to form the pattern photoresistlayer 5850. The pattern on the photoresist layer can be exposed to alaser writing process. For example, the printhead can be equipped with alaser source, which can run through the top surface of the photoresistlayer to form the pattern. Alternatively, other pattern layers can beused. For example, the printhead can print a pattern on the copper layer5840, using a plastic or polymer material.

In FIG. 58D, the pattern 5850 can be used to as a mask to etch thecopper layer 5840, e.g., removing portions 5845 of the copper layer 5840that are not protected by the pattern 5850. In FIG. 5E, the layer 5850is removed, for example, by an oxygen ashing process to removephotoresist, or by cooling the platform to reduce adhesion of theprinted plastic pattern, or by heating the platform to melt or vaporizethe pattern layer 5850, leaving a pattern copper layer 5860. Otherpatterning process can be used.

FIGS. 59A-59B illustrate top surfaces of patterned platforms accordingto some embodiments. In FIG. 59A, negative (e.g., reverse) protrudedpattern 5960 can be formed on platform 5930. In FIG. 6B, negative (e.g.,reverse) recess pattern 5965 can be formed on platform 5935.

In some embodiments, the present invention discloses a 3D printer systemhaving a patterned platform, such as a pattern support table or apattern wall or substrate. The patterned platform can be used to createpatterns, such as watermarks, on the surfaces of the printed material.The patterned platform can assist in improving adhesion of the objectwith the platform, for example, reducing or preventing lateral motionsof the object relative to the platform.

In some embodiments, a user can prepare the pattern on a coatedplatform. A platform can be precoated with a thermal conductive layer,such as a copper layer. The user can load the platform to a 3D printer.The 3D printer can print a pattern of the platform, such as a plasticpattern. The platform can be exposed to an etch solution, such assulfuric acid to etch the copper layer. The pattern then can be removed,such as by cooling the platform to reduce the adhesion of the plasticlayer with the platform so that the plastic layer can be removed.Alternatively, another etch solution can be used to etch the plasticlayer, such as acetone or a solvent chemical.

In some embodiments, a platform can be precoated with a thermalconductive layer, such as a copper layer, and a photosentive layer, suchas a photoresist layer. The user can load the platform to a 3D printer.The 3D printer can have a laser head, which can expose thephotosensitive layer to the laser light. The platform can be exposed toan etch solution, such as sulfuric acid to etch the copper layer. Thepattern then can be removed, such as by ashing the photosensitive layeror by etching the photosensitive layer with an etch solution.

FIGS. 60A-60C illustrate flow charts for 3D printer systems havingpatterned platforms according to some embodiments. In FIG. 60A,operation 6000 patterns a platform to achieve a negative image.Operation 6010 assembles the platform in a 3D printer system, whereinthe platform is operable to generate the image on a printed object. Forexample, the platform has an embedded or protruded image, which can betransferred to the object during the printing process. The depth of theembedded image, or the height of the protruded image, can be less thanthe dimension of a printed layer, such as less than 1 mm, or less than0.5 mm, or less than 0.1 mm, such as about 0.78 mm.

In FIG. 60B, operation 6030 coats a layer on a platform. The layer canbe a copper layer, having thickness less than 1 mm, or less than 0.5 mm,or less than 0.1 mm, such as about 0.78 mm. The platform can be analuminum substrate, having thickness less than 10 mm, such as less than5 mm, or about 3 mm. Operation 6040 patterns the copper layer to achievea negative image. Operation 6050 assembles the platform in a 3D printersystem.

In FIG. 60C, operation 6070 provides a 3D printer having a patternedplatform. Operation 6080 3D prints an object on the patterned platform,wherein the patterned platform is configured to imprint an image on theprinted object.

In some embodiments, the temperature controlled platform can include aPeltier device, which is a device that can heat or cool a substratebased on the polarity of an applied voltage to the Peltier device. ThePeltier heated build platform can provide both heating and coolingcapability. During operation, a voltage or current is applied to thePeltier device to heat the platform. When the object is printed, acontroller can simply reverse the voltage or current that is applied tothe Peltier device. The Peltier device would become cold and that couldmake the object pop off, assisting in factory automation.

In some embodiments, a voltage having a first polarity is applied to thePeltier device to heat the platform. The printer system can be operableto print an object on the heated platform. The heated platform canassist in improving an adhesion between the printed object and theplatform during the printing process. After the printing is completed, avoltage having a reverse polarity is applied to the Peltier device tocool the platform. The cooled platform can reduce the adhesion betweenthe printed object and the cooled platform, allowing removing theprinted object from the platform.

FIGS. 61A-61B illustrate a printing process for a printer having atemperature controlled platform according to some embodiments. In FIG.61A, a printhead 6110 can include a heater 6115 for heating the materialdelivered to the printhead. A Peltier device 6135 can accept a voltagehaving a first polarity 6136 for heating the support platform 6130.After the platform 6130 is heated, the printhead 6110 can start printingobject 6120 on the platform. The heated platform can cause the object6120 to stick to the platform.

In FIG. 61B, the printing process is complete, forming object 6125. ThePeltier device 6135 can accept a voltage having a reverse polarity 6137for cooling the platform 6130. The cooled platform can cause the object6125 to lose adhesion 6170 between the object and the platform. Thereduced adhesion can assist in removing the object from the platform.

In some embodiments, the present invention discloses a platform having aPeltier device to control the temperature of the platform. The Peltierdevice can provide an easy way to remove a printed object from theplatform, for example, by reversing a polarity of the Peltier device.

FIGS. 62A-62B illustrate flow charts for printer systems having aPeltier device platform according to some embodiments. In FIG. 62A, aprinter system platform can be incorporated with a Peltier device forcontrolling the temperature. Operation 6200 couples a Peltier device toa 3D printer platform. The Peltier device can be configured to heat theplatform during printing and to cool the platform when printing iscompleted.

In FIG. 62B, an operation of a printer system can include applying avoltage having a first polarity during printing, and then reverse thepolarity for removing the printed object. Operation 6220 applies avoltage having a first polarity to a Peltier device to heat a platform.Operation 6230 prints, by a 3D printhead, an object on the heatedplatform. Operation 6240 switches polarity of the voltage to cool theplatform. The cooled platform can cause the object to lose adhesion withthe platform.

What is claimed is:
 1. A 3D printer system for printing an object, the3D printer system comprising a printhead module, wherein the printheadmodule comprises at least a first mechanical interface and at least afirst electrical interface, wherein the at least a first mechanicalinterface and the at least a first electrical interface are configuredto be removably coupled with at least a printhead of two or moreprintheads, wherein the at least a first printhead of the two or moreprintheads comprises a printing characteristic different from at least asecond printhead of the two or more printheads; a platform module,wherein the platform module is configured to support a workpiece; amotion module, wherein the motion module is configured to move theprinthead module relative to the platform module; and a controllermodule, wherein the controller module is configured to communicate withthe at least a first printhead by recognizing a printing characteristicof the at least a first printhead when the at least a first printhead isinstalled in the printhead module.
 2. A 3D printer system as in claim 1,wherein each of the two or more printheads is configured to be removablyand exchangeably installed in the printhead module through the at leasta first mechanical interface and the at least a first electricalinterface.
 3. A 3D printer system as in claim 1, wherein each of the twoor more printheads comprises a second mechanical interface and a secondelectrical interface, wherein the second mechanical interface isconfigured for removably coupling with the at least a first mechanicalinterface of the printhead module, and wherein the second electricalinterface is configured for removably coupling with the at least a firstelectrical interface of the printhead module.
 4. A 3D printer system asin claim 1, wherein the at least a first printhead of the two or moreprintheads is installed in the printhead module, and wherein the atleast a second printhead of the two or more printheads is not installedin the printhead module.
 5. A 3D printer system as in claim 1, whereinat least one of the difference in the printing characteristic comprisesa difference in printing materials of the at least a first printhead andthe at least a second printhead, the difference in the printingcharacteristic comprises a difference in a maximum temperature of the atleast a first printhead and the at least a second printhead, thedifference in the printing characteristic comprises a difference in aconfiguration of the at least a first printhead and the at least asecond printhead, or the difference in the printing characteristiccomprises a difference in a delivery system configured to deliver aprinting material of the at least a first printhead and the at least asecond printhead.
 6. A 3D printer system as in claim 1, wherein thecontroller module comprises a first characteristic profile for the atleast a first printhead of the two or more printheads, and wherein atleast a characteristic of the first characteristic profile is differentfrom a corresponding characteristic of the second characteristic profilefor the at least a second printhead of the two or more printheads.
 7. A3D printer system as in claim 1, wherein the controller module comprisesa first characteristic profile for the at least a first printhead of thetwo or more printheads, wherein the controller module comprises a secondcharacteristic profile for the at least a second printhead of the two ormore printheads, and wherein at least a characteristic of the firstcharacteristic profile is different from a corresponding characteristicof the second characteristic profile.
 8. A 3D printer system as in claim1, wherein the controller module is configured to communicate with theat least a second printhead by recognizing a printing characteristic ofthe at least a second printhead when the at least a second printhead isexchanged with an installed printhead in the printhead module.
 9. A 3Dprinter system as in claim 1, wherein the mechanical interfaces and theelectrical interfaces are integrated.
 10. A 3D printer system as inclaim 1, wherein the at least a first electrical interface comprises awireless communication for a non-contact electrical connection betweenan installed printhead of the two or more printheads and the printheadmodule or the controller.
 11. A 3D printer system as in claim 1, whereinthe at least a first electrical interface is configured to behot-swappable with the at least a first print head.
 12. A 3D printersystem as in claim 1, further comprising an electrical alignment circuitcoupled to at least one of the printhead module and an installedprinthead of the one or more printheads, wherein the electricalalignment circuit is configured to provide an offset distance of theinstalled printhead configured for the controller to locate locations ofthe installed printhead.
 13. A 3D printer system as in claim 1, furthercomprising an automatic printhead exchanger mechanism, wherein theautomatic printhead exchanger mechanism is configured to automaticallyexchange an installed printhead of the two or more printheads in theprinthead module.
 14. A 3D printer system as in claim 1, furthercomprising two or more workpiece supports, wherein the two or moreworkpiece supports are configured to be exchangeably installed in theplatform module, wherein at least a first workpiece support of the twoor more workpiece supports comprises a characteristic different from atleast a second workpiece support of the two or more workpiece supports.15. A 3D printer system as in claim 1, further comprising two or moreworkpiece supports, wherein the platform module comprises a thirdelectrical interface for removably coupling with a workpiece support ofthe two or more workpiece supports, wherein the two or more workpiecesupports are configured to be exchangeably installed in the platformmodule through the third electrical interface, wherein at least a firstworkpiece support of the two or more workpiece supports comprises acharacteristic different from at least a second workpiece support of thetwo or more workpiece supports.
 16. A 3D printer system as in claim 1,wherein the controller module is coupled to a controlled area networkbus (CAN bus), wherein the CAN bus is coupled to the at least firstelectrical interfaces; wherein the controller module is configured toautomatically configure an installed printhead through the CAN bus,wherein the automatic configuration comprises loading printingcharacteristics of the installed printhead.
 17. A 3D printer system asin claim 1, wherein the controller module is coupled to a controlledarea network bus (CAN bus), wherein each of the two or more printheadscomprises a controlled area network (CAN) node for coupling to the CANbus through the first electrical interfaces for communicating with thecontroller module, wherein the CAN node comprises a controller havinginformation related to configurations of the printheads.
 18. A 3Dprinter system as in claim 1, wherein the controller module is coupledto a controlled area network bus (CAN bus), wherein the printhead modulecomprises a controlled area network (CAN) node coupled to the CAN busfor communicate with the controller module.
 19. A 3D printer system forprinting an object, the 3D printer system comprising a printhead module,wherein the printhead module comprises at least a first mechanicalinterface and at least a first electrical interface, wherein the atleast a first mechanical interface and the at least a first electricalinterface are configured to be removably coupled with at least aprinthead of two or more printheads through at least a second mechanicalinterface and at least a second electrical interface of the at least aprinthead, wherein the at least a first printhead of the two or moreprintheads comprises a printing characteristic different from at least asecond printhead of the two or more printheads, a platform module,wherein the platform module is configured to support a workpiece; amotion module, wherein the motion module is configured to move theprinthead module relative to the platform module; a controller module,wherein the controller module comprises a first characteristic profilefor the at least a first printhead of the two or more printheads and asecond characteristic profile for the at least a second printhead of thetwo or more printheads, wherein the first characteristic profile isdifferent from the second characteristic profile, wherein the controllermodule is configured to communicate with the at least a first printheadby assessing the first characteristic profile of the at least a firstprinthead when the at least a first printhead is installed in theprinthead module.
 20. A 3D printer system for printing an object, the 3Dprinter system comprising a printhead module, wherein the printheadmodule comprises at least a first mechanical interface and at least afirst electrical interface, wherein the at least a first mechanicalinterface and the at least a first electrical interface are configuredto be removably coupled with at least a printhead of two or moreprintheads, wherein the at least a first printhead of the two or moreprintheads comprises a printing characteristic different from at least asecond printhead of the two or more printheads, a platform module,wherein the platform module is configured to support a workpiece; amotion module, wherein the motion module is configured to move theprinthead module relative to the platform module; a controller module,wherein the controller module is coupled to a controlled area networkbus (CAN bus), wherein each of the two or more printheads comprises acontrolled area network (CAN) node for coupling to the CAN bus throughthe at least a first electrical interface, wherein the controller moduleis configured to automatically communicate with the at least a firstprinthead through the CAN bus by recognizing a printing characteristicof the at least a first printhead when the at least a first printhead isinstalled in the printhead module.